Start by selecting a narrow carbon brush preferably a stock size that's available with a spring and a shunt (braided copper wire inserted in the brush). Find a brush bushing suited to the brush (one less damn thing to make)
This place seems to be a one stop shop:
http://www.helwigcarbon.com/products...n-brushes.html
Make a face slip ring from copper faced FP4 fiberglass/epoxy circuit board material. The slip ring conductors take the form of concentric copper circles like a target. Make it two sided with a target on each side. Make each ring as wide as the brush. Drill through and slip 1/32 brass wire. solder both sides, and dress flush. One side is the ship ring the other is solder pad for the connecting wire. Rhodium Dalic plate would be a nice final touch if high reliability is an issue.
You can make the first few prototypes on a lathe by machining the copper from between the slip rings.
All that left is brush rigging and a mount.
Or you could cop out and buy what you need off eBay for about $7:
http://www.helwigcarbon.com/products...n-brushes.html
Or if you wish, the component approach for $35:
http://www.ebay.com/itm/KYS06-6-Wire...8#ht_811wt_867
This place seems to be a one stop shop:
http://www.helwigcarbon.com/products...n-brushes.html
Make a face slip ring from copper faced FP4 fiberglass/epoxy circuit board material. The slip ring conductors take the form of concentric copper circles like a target. Make it two sided with a target on each side. Make each ring as wide as the brush. Drill through and slip 1/32 brass wire. solder both sides, and dress flush. One side is the ship ring the other is solder pad for the connecting wire. Rhodium Dalic plate would be a nice final touch if high reliability is an issue.
You can make the first few prototypes on a lathe by machining the copper from between the slip rings.
All that left is brush rigging and a mount.
Or you could cop out and buy what you need off eBay for about $7:
http://www.helwigcarbon.com/products...n-brushes.html
Or if you wish, the component approach for $35:
http://www.ebay.com/itm/KYS06-6-Wire...8#ht_811wt_867
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