Hey Mike,

I ordered brushes for my Bosch (240) alternators recently. They came exactly as I've always received them, with soft silicone rubber tubing -- no metal parts aside from the brushes themselves. Well, the tubing is clear instead of white, like it used to be. Maybe you can post a pic or tell more about where you found them, etc.

As for the length question, I can tell you how I've done it: The silicone tubing is trimmed to 3/4" and the brush pulled in against the spring until it is just enough so it won't jam or cock in the holder. I am guessing that leaves about 7/16" of brush sticking out. I could measure a set, but I'm behind the game right now and have a few regulators to fix up.

I use a clip to hold the wire back while soldering so I don't have to re-crimp the eyelet.







--
Art Benstein near Baltimore

What Thomas Edison's Mother might have said to her son:
"Of course I'm proud that you invented the electric light bulb. Now turn it off and get to bed!"

These jokes should be in Alt.ernating