Did you also cut the mica between the comm bars? If yes and still arcing I would take a reading across all the bars with a VOM or better a growler and I think that you might have one that is bad. I guess that you also replaced the brushes and they are not sticking. Also check the field for resistance across both sides and they should be about the same, any major variance would indicate the field is bad. Let me know if you need more assistance.
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