Foot Controller Rewiring Tutorial
 

How to rewire a Foot Controller, Step By Step in Pictures. With Text instructions.

I got lucky and was able to get the back plate off in one piece. This shows how it is wired from the factory. I always take a picture before I start cutting anything. If need be, you can always refer back to it if you have a question on how it was wired originally.




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These wires were riveted on. Cut the wire about an inch from the end and strip off the insulation.

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With the insulation off, twist the wires so they are neatly wound together without any stray strands hanging out.

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Use flux and electrical solder and "Tin" the wires.

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Trim off the excess length.

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"Tin" the ends of the new wires that are to be soldered on to the old wires that have already have been "Tinned" and solder them together.


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This shows the new wires soldered together with the old and back in the fixture. Make sure that you put a knot in the wires so they don't get pulled out.

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Tuck the wires in and put the cover back on.

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Tin the ends of the wires that are going to the foot controller itself. Pull the wires into the foot controller and make a safety knot. Bend the newly tinned wires to form a loop. I wrap them around a screwdriver shaft to get a more uniform curve.

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Connect the ends to the terminals wrapping the wire around in a clockwise direction. This will prevent the wire from slipping off as you tighten the screw.

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To Be Continued.....

Finished! I like to use new extension cords to rewire these. I cut off the female end so I have a nice factory plug end. It is safer, neater, and looks good too.

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I hope this helps.
~Grant~
p.s. I am sorry about the font problem at the top.

Thanks for the tute.

I've done a number of those cord blocks too. I do them a bit different, but that's a good easy way.

Joe

thanks for the tutorial. this is such valuable information, i copied the tut to the Tutorials Forum. but the pictures didn't come out quite right.... but they are all still there.

Thank you Nancy. I also did a Tutorial on Rewiring motors. Maybe I should try to put that one in there too.
~G~