Hello Admiral,
Originally, I designed a copper leaf brush and clamping system for the dynamo, however, the scale was just too small for my skills to make the design work. Instead, I am using the ends of the wire leads as brushes and the wire insulation isolates the conductor so the brush holder does not have to be insulated from the other metal components. I selected an 18 AWG silicone coated stranded wire with 150 very fine, tinned wires. The cable is extremely flexible.
When I made the connections, I tried to use small strips of electrical tape to insulate the joints, however, the tape would normally fall off or unravel after a couple of days in the shop. While searching for an alternative, I came across this Liquid Tape product on Amazon.com. I comes in multiple colors and and can be brushed on the joints to insulate the connection. The material is very thick and I found that two coats work quite well. The dried material is quite flexible and has proven to be a good insulator. This is my first experience with the material but so far, it appears to work very well.
The product I purchased was made by Gardner Bender and available in many sizes. The label does not have any details about the product, however, there is a short description on the product web page. There were several companies selling the same product on Amazon.
Attached is a photo for the two bottles I purchased.
