I am wearing out brushes at a alarming rate . is there a good replacement brush available made out of something softer than brass .
The New Day brass brushes should last you 10,000 miles at least. There must be some problem, like the spring is perhaps too stiff or the timer body is not smooth inside to cause the brush to wear like that.
Since last summer's experiment that Mark posted above, I tried again. This time, instead of drilling a hole for the spring into the bottom of the brush, I used a shorter and lighter spring with no hole. So far it's working fine. For a retaining pin I made a little hole with a 1/16" bit and stuck a little piece of paper clip in it.