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Solenoid and Transformer Winding Jig.

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Patrick
Fri Sept 30 2011, 05:45AM Print
Patrick Registered Member #2431 Joined: Tue Oct 13 2009, 09:47PM
Location: Chico, CA. USA
Posts: 5639
My new coil winder for Solenoids and transformers.

Better description will be available after i sleep.


1317361553 2431 FT0 Jig
The whole thing, spool of mag wire, hand crank, and all-thread that carries the winding bobbin. (solenoid bobbin seen here)
\



1317362569 2431 FT1630 Materials

1317362569 2431 FT1630 Partsmic

1317362569 2431 FT1630 Pieces



1317362268 2431 FT1630 Assembly1

1317362268 2431 FT1630 Assembly2

1317362268 2431 FT1630 Assembly3

1317362268 2431 FT1630 Assembly4



1317362360 2431 FT1630 Final

1317362360 2431 FT1630 Hand
Finished solenoid winding bobbin.


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jpsmith123
Fri Sept 30 2011, 09:34PM
jpsmith123 Registered Member #1321 Joined: Sat Feb 16 2008, 03:22AM
Location:
Posts: 843
What kind of plastic is that? Teflon?

Is the idea to wind a coil on the form shown and then slide it off the plastic and eventually onto something else?
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Patrick
Fri Sept 30 2011, 09:38PM
Patrick Registered Member #2431 Joined: Tue Oct 13 2009, 09:47PM
Location: Chico, CA. USA
Posts: 5639
jpsmith123 wrote ...

What kind of plastic is that? Teflon?
White Pvc sheet 3mm thick, not quite solid, but not foamed either.



jpsmith123 wrote ...

Is the idea to wind a coil on the form shown and then slide it off the plastic and eventually onto something else?
yes, ill use Radhoos method for solenoids and transformer coils. mag-wire woud around wet epoxy, with no bubbles (i hope). But no vacuum needed either. Coil is 4 mm thick which is the max that radoo suggested.

EDIT: ill use castin' craft mold release to help ease the coils out.
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jpsmith123
Fri Sept 30 2011, 10:53PM
jpsmith123 Registered Member #1321 Joined: Sat Feb 16 2008, 03:22AM
Location:
Posts: 843
What size wire will you be using?
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Patrick
Fri Sept 30 2011, 10:55PM
Patrick Registered Member #2431 Joined: Tue Oct 13 2009, 09:47PM
Location: Chico, CA. USA
Posts: 5639
jpsmith123 wrote ...

What size wire will you be using?
35 Awg.
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Turkey9
Sat Oct 01 2011, 01:43AM
Turkey9 Registered Member #1451 Joined: Wed Apr 23 2008, 03:48AM
Location: Boulder, Co
Posts: 661
What's the application for the coils? The shape would suggest either a strange geometry on the core or some sort of brush less motor/generator.
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Patrick
Sat Oct 01 2011, 02:29AM
Patrick Registered Member #2431 Joined: Tue Oct 13 2009, 09:47PM
Location: Chico, CA. USA
Posts: 5639
It just pulls up a zip drive for a flying robot (IARC 6). An obround Laminated steelcore section will go through the center.
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Killa-X
Sat Oct 01 2011, 04:43PM
Killa-X Registered Member #1643 Joined: Mon Aug 18 2008, 06:10PM
Location:
Posts: 1039
Patrick wrote ...

jpsmith123 wrote ...

What size wire will you be using?
35 Awg.

Darn, I guessed 34 by the spool (Very similar to mine) Is the spool just riding on that copper tube? I understand 35awg is rather thin so you dont want to give it too much tension, and any sudden jolts would snap it.

Otherwise yeah, whatever works for you to wind your transformres =)
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Patrick
Sat Oct 01 2011, 04:59PM
Patrick Registered Member #2431 Joined: Tue Oct 13 2009, 09:47PM
Location: Chico, CA. USA
Posts: 5639
Killa-X wrote ...

Patrick wrote ...

jpsmith123 wrote ...

What size wire will you be using?
35 Awg.

Darn, I guessed 34 by the spool (Very similar to mine) Is the spool just riding on that copper tube? I understand 35awg is rather thin so you dont want to give it too much tension, and any sudden jolts would snap it.

Otherwise yeah, whatever works for you to wind your transformres =)
I got the 35 Awg dumpster diving in 1999 ! it looks like about 2000 yards of wire, said "heavy insulated" and "35Awg "which menas double layers of the insulant. And yes i have that huge spool on two end bearings so the thin wire doesnt stretch and craze, i got some mods to make but it should roll real easy. it's 0.0055 inches in diameter.
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