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Emerson 45641 "Longnose" Ceiling Fan Restoration Thread & Intro  Rate Topic 
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 Posted: Fri Aug 10th, 2018 04:37 pm
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Derek Warnecke
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Greetings!  I've just registered as a Guest here on AFCA and I'd like to introduce myself.
I'm a 29-year-old Electrical Engineer from Houston, TX on work assignment in Blacksburg, VA.  I started collecting ceiling fans about eight years ago, scavenging Hunter Originals exclusively from craigslist and garage sales.  Being in Texas, they were relatively plentiful.  As the years passed, I learned how to disassemble, clean, and eventually strip and repaint cast iron fans.  Now, with my house fully stocked with cast iron fans and storage becoming a bit of an issue, I've become more selective on what I collect and have turned my interest towards antiques exclusively.

Over the past few months I restored an Emerson Roundnose, circa 1941 that the seller rescued from a bar in Charleston, WV that was set to be demolished.  It was "hidden" above a drop ceiling - pretty cool.  A few months prior I picked up a chrome Hunter R-52, also circa 1941 which now hangs in my living room in TX.

Nothing will make you appreciate the craftsmanship of these old fans like stripping, cleaning, rewiring and reassembling one.  It's an involved, messy, but very rewarding endeavor.



I figured I was long overdue in making an account here on AFCA and taking advantage of the wealth of knowledge displayed by AFCA members -- I have drawn on this forum as a lurker many times, especially while restoring the Roundnose.  I intend on becoming a Full Member upon the next annual dues cycle in December.

Dispensing with introductions, I'd like to use this thread to catalog my current project -- restoring an Emerson 45641 "Longnose" ceiling fan that I picked up in St. Louis, MO last week.  It appears to be a mid-production run model, sporting a square tag.  The wiring appears to be original and untouched, including the two free leads running from the speed coil area to the switch housing.  The switch is intact and turns, but doesn't seem to "snap".  The fan does run as-is, but the rotor is gummy, as expected.









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 Posted: Fri Aug 10th, 2018 07:06 pm
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Richard Daugird
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Welcome from another Texan.

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 Posted: Fri Aug 10th, 2018 07:21 pm
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Stan Adams
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If you are in Houston the first weekend of October, come over to the Lake Houston fan meet. We would love for you to join us!

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 Posted: Fri Aug 10th, 2018 07:47 pm
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Derek Warnecke
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Stan Adams wrote: If you are in Houston the first weekend of October, come over to the Lake Houston fan meet. We would love for you to join us!
Sounds fun!  Unfortunately I don't foresee a trip back until around the holidays.  Every four months or so I make the trek from VA to TX, driving, since I usually have some heavy fans in tow.  I even fabricated a little rig out of pine to hold 3 fan motors upright for the drive.

Once I'm back in Houston for good, you'll see me around.  If there's ever any sort of fan swap/sale event in the area, I'll have quite a load of clean '70s & '80s Originals to sell if anyone is interested.

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 Posted: Fri Aug 10th, 2018 11:37 pm
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Tom Morel
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I like your taste in fans. Welcome to the club.

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 Posted: Sun Aug 12th, 2018 12:05 am
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Derek Warnecke
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Update: The snap switch is out. I polished up the switch cover to reveal what looks like copper. All of the parts of the switch appear to be accounted for, but it’s not snapping properly. Any ideas?









I also started removing paint and rust from the switch housing. Love the look of these in raw cast iron.



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 Posted: Fri Aug 24th, 2018 07:53 pm
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Derek Warnecke
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Update -- Fan is stripped and ready for priming.  I intend on hand wire brushing, dry wiping and then applying a final coat of lacquer thinner to prep the surface for priming.
Pic showing about 90% completion on paint stripping.  The bearing appears to be in great shape as well.








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 Posted: Sat Aug 25th, 2018 12:38 pm
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Derek Warnecke
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Update: Painting jig is put together.  Masked the inner laminations and shaft, prayed Dolph's insulating varnish on the top and bottom of the stator coils, cleaned off the excess and primed the top casting.  Really looking nice so far.













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 Posted: Sat Aug 25th, 2018 01:18 pm
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David Hoatson
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Welcome to the Antique Ceiling Fan Collectors Association (ACFCA ??), a close-knit group that is not afraid to climb a ladder and hold 60 pounds of iron over our heads. 

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 Posted: Mon Sep 10th, 2018 06:57 pm
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Derek Warnecke
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Quick update: All parts except for the irons have been primed, painted and clearcoated.
I spent yesterday stripping two layers of stubborn paint off the irons and priming them.  The blades, however, will require a complete strip, sand and stain job.  Any pointers on this?
















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 Posted: Mon Sep 10th, 2018 10:01 pm
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Tom Dreesen
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If you use a water based stripper such as Citrastrip, be advised the blades may want to warp on you.  You can weigh them down with thin cloth between them to dry, or use a solvent based stripper.

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 Posted: Wed Sep 19th, 2018 12:24 pm
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Derek Warnecke
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Update time:
The motor is pretty much complete, save for the pullchain retrofit (2-1/8" bottom plate with standard 3 speed pullchain mounted vertically, plate secured to original threaded mounting posts with standoffs).  All 3 speeds operate smoothly with not even a buzz from the coils - the Dolph's did it's job!  The rotor takes a solid two minutes to coast to a stop when power is removed.








The blades were indeed a real challenge.  They were coated with two layers of paint -- latex paint that was easily removed with stripper, and oil-based paint beneath that was extremely difficult to remove.  The only method that seemed to work was heating the paint with a heat gun and immediately scraping off the paint with steel wool.  This process took a good 45 minutes per side, so an hour and a half per blade.






Following that, I sanded with 150 and 220 grit sandpaper.





And stained with Minwax Sedona Red.  This stain, to my eye, emulates the blades Hunter used on the Original in the mid 80s.





The next day I sealed with Krylon clear lacquer, three coats.  Tomorrow I plan on wet sanding the blades with 600 grit to finish.

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 Posted: Wed Sep 19th, 2018 01:21 pm
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Craig Robbins
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Very nice

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 Posted: Wed Sep 26th, 2018 03:43 am
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Derek Warnecke
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Happy to report that it’s finished and ready for installation!









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 Posted: Thu Jan 3rd, 2019 04:50 pm
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Derek Warnecke
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I figured it was time to close the loop and show some pictures of the fan finally installed in my parents' living room back in New Braunfels, TX.  It matches the decor of the room and house perfectly!

The factory Low speed ended up being 170-180rpm, too fast for practical use.  We used a KBWC-15K 5A fan speed controller to take it down to about 80 rpm on the lowest speed setting (with the fan pullchain on high).

It runs smooth and silently and my parents adore it.  This is what it's all about!




Video here:

https://www.youtube.com/watch?v=0rAbBYsY6t4




Last edited on Thu Jan 3rd, 2019 04:54 pm by Derek Warnecke

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 Posted: Thu Jan 3rd, 2019 05:13 pm
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Allen Bennett
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Welcome to AFCA.  :clap:  Wanting an antique ceiling fan myself a few months back, I started watching You Tube videos for some ideas.  I think I watched all of yours.  I finally decided on an unrestored mid 40's Hunter that I purchased from fellow member Tom Dressen.

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 Posted: Fri Jan 4th, 2019 12:22 am
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Richard Daugird
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Great job, I hope you can come out to Galveston to the fan meet in February. I grew up in Friendswood, seems I knew someone named Warnecke. I'm 50, maybe I knew your dad, or another relative?

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 Posted: Fri Jan 4th, 2019 12:49 am
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Tom Dreesen
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Looks great Derek.  

You really need an "egg" to cover that adjustable hanger transition.  I have a few, but less than the adjustable hangers I have.





Attached Image (viewed 137 times):

DSC00861.JPG

Last edited on Fri Jan 4th, 2019 12:52 am by Tom Dreesen

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 Posted: Fri Jan 4th, 2019 12:12 pm
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Mel Lagarde
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Derek
Welcome to AFCA and you did a great job on the Emerson.  They are wonderful fans and it is great to see it in use.  I may have a two piece brass egg laying around I can send you to cover that adjustment knuckle.  

Mel

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 Posted: Fri Jan 4th, 2019 12:12 pm
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Derek Warnecke
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Richard Daugird wrote: Great job, I hope you can come out to Galveston to the fan meet in February. I grew up in Friendswood, seems I knew someone named Warnecke. I'm 50, maybe I knew your dad, or another relative?
I really wish I could, but I don't expect to visit Texas again until May or so.

I've been told that there are a few Warneckes in Friendswood.  My family is all from New Braunfels, though.  German Texan, through and through  :clap:

Last edited on Fri Jan 4th, 2019 12:13 pm by Derek Warnecke

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 Posted: Fri Jan 4th, 2019 12:14 pm
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Derek Warnecke
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Tom Dreesen wrote: Looks great Derek.  

You really need an "egg" to cover that adjustable hanger transition.  I have a few, but less than the adjustable hangers I have.


Thanks, Tom. I've been on the lookout for one.  Frankly I would have hung that fan on a standard hanger but I didn't have a spare and this fan came with that adjustable type.

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 Posted: Fri Jan 4th, 2019 12:17 pm
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Derek Warnecke
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Thanks, Mel. My parents are enjoying this one so much that I'm now working on a 36" Emerson 69641 early Roundnose model w/ one-piece oil cup/globe fitter for my dad's study.  Gotta replace those cheap-o Craftmades around the house with some real fans, after all  :cool:
PM me about that egg if you'd like.

Last edited on Fri Jan 4th, 2019 12:17 pm by Derek Warnecke

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 Posted: Fri Jan 4th, 2019 01:28 pm
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Derek Warnecke
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https://www.youtube.com/watch?v=EfovULtwz0M

And here it is running on the "Low" provided by the KBWC-15K, with my dad's commentary. Beautiful fan, effortless-less-lessly running :P

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 Posted: Fri Jan 4th, 2019 11:59 pm
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Richard Daugird
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Derek Warnecke wrote: https://www.youtube.com/watch?v=EfovULtwz0M

And here it is running on the "Low" provided by the KBWC-15K, with my dad's commentary. Beautiful fan, effortless-less-lessly running :P
Can one of those be used to power a desk fan? 

.
P.S. I take it your family is involved with Camp Warnecke in New Braunfels? That's why I remember the name.

Last edited on Sat Jan 5th, 2019 12:00 am by Richard Daugird

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 Posted: Sat Jan 5th, 2019 12:13 am
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Derek Warnecke
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Richard Daugird wrote: Derek Warnecke wrote: https://www.youtube.com/watch?v=EfovULtwz0M

And here it is running on the "Low" provided by the KBWC-15K, with my dad's commentary. Beautiful fan, effortless-less-lessly running :P
Can one of those be used to power a desk fan? 

.
P.S. I take it your family is involved with Camp Warnecke in New Braunfels? That's why I remember the name.


That’s us! More recently, the Warnecke Drive-In on Union St. That was still before my time, though; I’m a youngster.

I haven’t tried one on a desk fan. It’s a wall control:

KB Electronics Model KBWC-15K (UL) Variable Speed Fan Control, Wall Mount, Rated 5.0 Amps @ 120 VAC for use with Shaded Pole and PSC Motors

 https://www.amazon.com/dp/B001D2NUB0/ref=cm_sw_r_cp_tai_Iz.lCbXTKDE2S

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 Posted: Sat Jan 5th, 2019 12:29 am
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Tom Dreesen
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You can find them cheaper.  I bought about 15 from eBay at 5 each.

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 Posted: Sat Jan 5th, 2019 07:24 am
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Richard Daugird
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That's crazy Derek, I remember my friend always talking about Camp Warnecke, it finally sunk in when I called him. In wish you could make it next month. Some other time!

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