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If you own an electric drill, angle grinder, vacuum cleaner, or any tool with a universal motor, carbon brushes are one of the unsung heroes that keep things running. These small blocks of conductive material transmit current to the spinning armature; when they wear out, performance drops, motors spark, and tools can overheat. Think of carbon brushes as the sneakers on a runner — cheap to replace but essential to keep the race going. Replacing them at the right time saves you from buying a whole new tool and keeps repairs tidy and inexpensive.
Spotting worn brushes early is a fast way to extend the life of a motor. The most obvious signs include excessive sparking at the commutator, intermittent power or loss of torque, a grinding or rattling noise that wasn’t there before, and, in some appliances, a burning smell. If your tool only runs on higher settings or develops erratic speed, worn brushes may be the culprit. Ignoring these signs is like driving on bald tyres — you’ll eventually pay a higher price.
Some sparking is normal when brushes engage the commutator, but heavy, continuous sparks or smoke indicate the brush has worn unevenly or the commutator is damaged. Replace the brushes and inspect the commutator surface to avoid further harm.
If your drill stalls under light loads or the motor cuts in and out, chances are the brush has reached a critical length or the spring tension has dropped. That intermittent contact causes voltage drops and reduced motor efficiency.
Grinding, buzzing, or clicking that lines up with motor speed can suggest that a brush is stuck in its holder or the spring has failed. Catching this early prevents damage to the armature and bearings.
Not all brushes are created equal. Choosing the right material affects performance, life span, and the amount of commutator wear. Typical materials include graphite, copper-graphite, and electrographitic blends. Each has its strengths depending on the motor design and application.
Graphite brushes are soft, provide gentler contact and are often used where low wear to the commutator is required. They’re great for light-duty tools and appliances and tend to be quieter during operation.
Copper-graphite mixes are harder and carry higher current, which makes them suitable for heavy-duty power tools like angle grinders and large drills. They last longer under load but can wear commutators a bit faster than pure graphite.
Electrographitic brushes handle high temperatures and heavy current loads and are common in professional or industrial motors. Resin-bonded brushes are used where a balance of properties is needed. Always check manufacturer recommendations before swapping materials.
Measuring a brush correctly is the fastest way to find a match. Use a small ruler or caliper and note the brush’s length, width, and thickness in inches. Also measure any shank, wire lead, or terminal length in inches. If the brush has a spring attached, measure the spring length too. Record the dimensions as fractions or decimals of an inch — for example, 3/4" long, 1/4" wide, and 1/8" thick — to improve your match accuracy when buying online or in-store.
Don’t forget to measure the brush holder inside the tool and the length of the wire lead: a brush with a lead that’s 2" too short may be useless. Also check the mounting style — whether the brush is screw-mounted, clipped, or has a push-fit tab — and note it when searching for replacements.
Compatibility goes beyond size. Look for part numbers stamped on the old brush, check manufacturer cross-reference tables, and consider the motor’s voltage and duty cycle. Using the correct brush chemistry and spring tension ensures the motor runs smoothly and avoids premature wear. If the tool manual lists an OEM part number, start from that, then use cross-reference guides from reputable suppliers to find compatible aftermarket replacements.
Part numbers are a shortcut to compatibility. Most UK suppliers and manufacturers maintain cross-reference charts so you can match OEM numbers to their own stock or third-party equivalents. Keep a photo of the old brush and its part number handy when shopping online or in-store.
Shopping for brushes in the UK gives you plenty of options: specialist electrical distributors, DIY chains, tool retailers, and general marketplaces. Each has its strengths, from fast local pickup to large inventories and technical support. Below are some reliable places to start your search.
Screwfix is great for tradespeople who want fast local collection or next-day delivery. They stock both branded and generic brush sets for common power tool makes and often list cross-reference part numbers. Their stores make it easy to compare sizes in person if you bring your old brush along.
Toolstation offers a wide selection of replacement brushes and brush kits, with competitive pricing and many branches across the UK. Their online filtering by tool brand can help you narrow down options quickly, and they often carry brush holders and springs too.
RS Components is a professional supplier with a deep catalogue for industrial and specialist brushes. If you run into obscure part numbers or need electrographitic grades, RS is a good bet, and their technical data sheets are very helpful for matching materials.
Machine Mart supplies both hobbyists and workshops with tool spares, including carbon brushes and armature accessories. Their pack sizes and brush kits cater to users who repair multiple tools, offering a pragmatic middle ground between consumer and industrial ranges.
For DIYers who want convenient local availability, B&Q and Wickes sell a modest range of replacement brushes and brush kits for common household tools. These retailers are best for basic, quick replacements rather than specialised or hard-to-find brushes.
Draper Tools and Cromwell carry a broad range of replacement parts aimed at trade users. They often stock both branded and universal brush kits, plus accessories like commutator polishing kits and brush grips, making them useful one-stop shops for small motor repairs.
Marketplaces like Amazon UK and eBay offer massive variety and competitive pricing. You can find OEM replacement packs and obscure sizes that aren’t stocked locally. Be cautious: verify seller ratings, read reviews, and check return options since variations in quality exist.
Smart shopping can shave pounds off repair costs and prevent avoidable returns. Buy brush kits that include multiple sizes, keep an old brush as a template, and consider buying spare pairs for your most-used tools. Generic brushes can be cheaper but confirm material match and fit. If a brush is slightly thicker, you may be able to sand it to size; if it’s longer, it can usually be trimmed safely in small amounts. When in doubt, spending a little more on a quality or OEM part can pay off in longer life and improved performance.
Brush kits bundle common sizes and often cost less per brush, perfect if you maintain several tools. Keep a kit in your workshop for quick fixes so a breakdown doesn’t delay your work.
OEM brushes are matched to the tool maker’s specifications but cost more. High-quality aftermarket brushes can offer excellent value, but verify material and spring tension. Look for reputable brands or seller guarantees.
Replacing carbon brushes is a straightforward task for most hobbyists. With a few basic tools and a careful approach it can take as little as 10 to 30 minutes per tool. Below is a simple step-by-step guide to get you started.
Always unplug the tool or remove the battery before starting. Wear eye protection and keep loose clothing away from moving parts. If the tool was recently used, let it cool down before you touch the motor.
Most tools have brush caps or small covers near the motor housing. Remove screws and gently pull out the brush holder or cap. Take a photo of the brush orientation and wiring before touching anything; this saves guesswork during reassembly.
Remove the old brush and note its measurements, wire lead length, and mounting style. Compare to your new brush to confirm size and terminal fit. If the brush is spring-loaded, release the spring slowly to avoid damaging the holder.
Slide the new brush into the holder, connect the lead or terminal, and ensure the spring applies light pressure. Reassemble the tool and run it at no-load speed for a minute or two to seat the brush to the commutator. Listen for steady operation and minimal sparking.
Little habits go a long way. Keep commutators clean, avoid overloading your tools, and store them in dry places to reduce corrosion. Regularly inspect brushes for even wear and replace them before they reach the wear line. Cleaning with a soft brush and using a commutator cleaner or a polishing stick will minimize arcing and prolong both brushes and armature life.
Make a habit of checking brushes every few months if you use tools frequently. Note wear patterns and listen for new noises. A quick inspection often catches problems while they’re cheap to fix.
Some jobs are better left to a trained technician, especially if the armature is scored, the commutator requires turning, or bearings need replacing. If you see heavy pitting, burnt windings, or major commutator damage, professional repair or replacement may be the most cost-effective and safest option. Professionals have lathes and testers to restore commutators and balance armatures correctly.
Replacing carbon brushes is one of the most cost-effective ways to keep power tools and appliances in service. With the right measurements, a little research on material and compatibility, and a few reliable UK suppliers to hand, you can often fix problems in under an hour. Think ahead: keep basic spare brushes in the workshop, and treat maintenance like preventive medicine for your tools.
Whether you’re a DIY enthusiast or a tradesperson, knowing how to pick, measure, and replace carbon brushes will save you time and money. Use reputable UK retailers like Screwfix, Toolstation, RS Components, Machine Mart, and specialist suppliers to find the right match. Measure in inches, check material and fit, and don’t be shy to invest in quality when it matters. With basic care and timely replacements, your tools will repay you with longer life and more reliable performance.
| Carbon Brushes | Price | |
|---|---|---|
| Kulbørste - Starts | kr. 13,15 |
