If you replace the carbon brushes on your Henry Hoover motor without cleaning the commutator, you’re asking for trouble. The motor can still spark badly, and your new brushes could be ruined in minutes.
In this guide, I’ll show you how to safely clean the commutator on your Henry (or Hetty, James, Charles, etc.) so your repair lasts — and Henry runs like new again.
Step 1 – Remove the Old Carbon Brushes
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On newer models, the carbon brushes come pre-fitted in holders.
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On older models, you’ll need to swap the worn carbon inserts into the existing holders.
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Clean inside the holders with fine sandpaper, check the new inserts move freely, and clip them into place.
Step 2 – Prepare to Clean the Commutator
The commutator is the copper ring on the motor armature where the brushes make contact. If it’s blackened, rough, or grooved, it must be cleaned.
What you’ll need:
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600-grit aluminium oxide sandpaper (cut into a thin strip).
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A drill with a 10mm socket to spin the armature.
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A clean cloth and compressed air for dust removal.
Step 3 – Sand the Commutator
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Wrap the strip of sandpaper around the commutator.
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Spin the motor gently with the drill.
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Hold the paper firmly so it polishes the copper surface evenly.
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Keep stopping to check your progress — repeat until smooth and shiny.
👉 Expect to do this a dozen times or more for a good finish.
Step 4 – Clean Between the Contacts
Once the commutator is shiny again:
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Use a sharp blade to carefully scrape between each copper segment.
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This removes burrs and ensures proper separation of the contacts.
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Finally, blow away all carbon dust with compressed air.
Step 5 – Refit Your Carbon Brushes
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Install the new brushes back into the holders.
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Refit the motor into Henry.
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Run the vacuum on full power for a short time to bed the brushes in smoothly.
Why This Step is Essential
Skipping the commutator clean is like fitting new brake pads on a rusty disc — it won’t work properly, and you’ll just be back to square one.
Take a few minutes to do it right, and your Henry motor will run smoothly for years.
Final Result
A freshly polished commutator, new carbon brushes, and Henry back to life.