64C Charging issues

[BK911]

64C with 12V conversion
Gen warning light came on at low rpms.
Grounded Df and had >13V at D+
Swapped out VR with used spare.
Now Gen warning light comes on at high rpms.
V at D+ was 4.8@500, 6.5@1000, 12.3@1500, 14.3@2000, 13.8@2500 and bounced around too much to measure at higher rpms.
Brushes stick out maybe 2-3mm past the holders.
Nice grooves on the "thingy".
Used sand paper on the thingy with engine running to clean it up.
Not sure what to do next???
Replace VR with a new one?

Wasn't a big deal until I had to start using the headlights on the way to work.

Thanks!
BK
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'72 914 1.7
'74 Standard Bug 1600

[Starbucket]

Blow out the thingy and replace the brushes. The grit from the sand paper probably got embedded in the brushes and the groves. Put the original VR that you swapped out back and make sure you polarize it before wiring it in. Slight flicker at idol is normal with lights on. The proper way to polish the thingy is follow (after polishing with sand paper) with a peace of hard wood and burnish the thingy(smooth out the micro high spots so the brushes get full contact). Burnish = press firmly with hard wood block back and forth while spinning the thingy.

[BK911]

Thanks starbucket.
Played around a bit last night.
The thingy looks like I may have damaged it with the sand paper.
Does it look fixable?
The block of hardwood will smooth it out, but what about the silver color?

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'72 914 1.7
'74 Standard Bug 1600

[Starbucket]

The silver color is from the brushes arcing as they were losing contact with the thingy, not to worry, but I can see from the pic. your brushes are worn out. autohauseaz.com might have them. Try some crocous cloth sandpaper or 600 wet&dry to smooth the grooves down some, before the hard wood.