Carbon Brushes, Batteries and Blades: Keeping Power Tools Alive

A $40 carbon brush set can save a $300 tool. Know which parts wear and replace them on time.

Carbon brushes

Brushed motors die when brushes wear below ~5 mm. Symptoms: intermittent power, sparking, burning smell. Replacement takes 10 minutes on most DeWalt, Makita and Bosch tools — match the brush holder dimensions and spring type.

Battery packs

Li-ion packs fade after 300–500 cycles. If your 18V pack dies mid-cut, a replacement pack (or a rebuilt cell set) restores full runtime. Store batteries at ~50% charge in cool, dry places.

Blades and accessories

Blade choice matters more than brand: 24T for fast rough cuts, 60T+ for clean plywood and laminate. Diamond blades for tile and stone. Replace blades when cuts burn or wander.

Stock up in our carbon brushes and blades collections.