Abstract: An armature conductor to commutator bar connection. The bars of the commutator have radially extending slots that are defined by surfaces that taper outwardly. The ends of the armature conductors are formed to a generally wedge-shaped configuration such that the side surfaces are tapered inwardly. After the ends of the armature conductors have been formed to the tapered shape they are pushed into the slots of the commutator bars to such a depth that there is an interference fit between the side surfaces of the ends of the armature conductors and the tapered walls of the slot to lock the ends of the armature conductors to the commutator bars. After the ends of the formed armature conductors have been pushed into the slots, portions of the commutator bars are staked over into engagement with the top armature conductor end.

Abstract: A starter solenoid for electric starting apparatus and its method of manufacture. The solenoid has hold-in and pull-in coils and a cap formed of insulating material that carries a start switch terminal and a motor terminal. Both terminals have axially extending internal bores and when the cap is moved into engagement with the case of the solenoid to secure it thereto end lead wires of the coils are inserted into the bores of the terminals. The terminals are radially crimped into engagement with the wires and the crimped portions are then welded to the wires. The ground connection for one end of the hold-in coil is made by inserting an end lead wire of the hold-in coil into the bore of a hollow metallic terminal that is carried by a metallic plate member, crimping the terminal to the wire and then welding the crimped portion to the wire.

Abstract: A starter solenoid for electric starting apparatus and its method of manufacture. The solenoid has hold-in and pull-in coils and a cap formed of insulating material that carries a start switch terminal and a motor terminal. Both terminals have axially extending internal bores and when the cap is moved into engagement with the case of the solenoid to secure it thereto end lead wires of the coils are inserted into the bores of the terminals. The terminals are radially crimped into engagement with the wires and the crimped portions are then welded to the wires. The ground connnection for one end of the hold-in coil is made by inserting an end lead wire of the hold-in coil into the bore of a hollow metallic terminal that is carried by a metallic plate member, crimping the terminal to the wire and then welding the crimped portion to the wire.

Abstract: A method for resistance welding zinc-coated steel members is described wherein at least one member comprises a copper layer intermediate the steel and the zinc coating. The copper layer melts during welding and seals fissures within the fused steel to produce a hermetic weld. The copper layer also protects exterior surfaces where the zinc coating is disrupted by the welding operation.