My old saber saw won’t cut worth a damn-it stalls when I try to cut anything thicker than 1/4" plywood. It is quite old, and I notice the commutator sparks a lot-are worn-out brushes the problem?
And, how do I get new brushes for a 30 year old saw?
Are the brushes on it replaceable? Is there a spot on each side of the case around the motor area that you can access the brushes from?
What’s the make/model?
Have you checked the manufacturers website for replacement parts?
easy user serviceable tools allow brush replacement without dismantling the tool.
other tools need care to dismantle and reassemble with all the parts in places. to replace brushes having four hands and good dexterity is at least handy if not needed.
if you can’t find replacement parts for model you might find generic parts. mom and pop hardware stores are good sources for parts and advice.
The brushes are always replaceable with some work. Since your tool apparently does not offer access screws on the sides, you will have to disassemble it to get to them. Brushes are cheap and available at some hardware stores. There are some standards to the sizes so you might even order some somewhere. The jig saw is not complicated. The brush holder usually has a clip that holds the wire. You’ll have to play it by ear. If you have used to tool too long with worn brushes, the armature may also be damaged.
It sounds like you should just buy another one for $15. They sell them that cheap at my ACO hardware store.
Brushes are cheap and worth a try, but it is also possible you have a shorted winding, which will cause much commutator sparking, heat, and low speed and torque.
When you replace the brushes, it is good to clean the commutator segments, and between them as well as possible. Cutting on a lathe is best, but you can do some good with abrasive paper if you take care to remove any left over grit with an old toothbrush or similar. Ideally the mica (or modern substitutes) is trimmed below the level of the segments.
I actually have a small hand cranked tool for doing the above work without a lathe…got it cheap, as the PO had no idea what it was for.
Buy a new one. Replacing brushes can be a pain, especially if the saw wasn’t designed for easy access. New ones are cheap.
a repair attempt will cost you less than $2 if it is brushes. if the tool is otherwise still functioning well then try it. you need to be observant, dexterous and organized to disassemble and reassemble successfully.
if you don’t repair it yourself (or find someone to do it for you) then give it to a thrift store or otherwise pass it on (letting its condition be known).
Over many years I made a practice of taking every tool apart and doing a forensic check before salvaging all the usable parts, which might include only the brushes and switch in this case. As a result I have drawers of brush assemblies available. I could take that jig saw apart and find something in my shop that would work. When you factor in the poster making a trip to the store or two stores for brushes, it just doesn’t pay to attempt it unless it’s a fire drill. Also, if the tool is a single or double speed rather than variable, just kick yourself for not replacing it sooner.