If you need assistance, please send an email to forum at 4hv dot org. To ensure your email is not marked as spam, please include the phrase "4hv help" in the subject line. You can also find assistance via IRC, at irc.shadowworld.net, room #hvcomm.
Support 4hv.org!
Donate:
4hv.org is hosted on a dedicated server. Unfortunately, this server costs and we rely on the help of site members to keep 4hv.org running. Please consider donating. We will place your name on the thanks list and you'll be helping to keep 4hv.org alive and free for everyone. Members whose names appear in red bold have donated recently. Green bold denotes those who have recently donated to keep the server carbon neutral.
Special Thanks To:
Aaron Holmes
Aaron Wheeler
Adam Horden
Alan Scrimgeour
Andre
Andrew Haynes
Anonymous000
asabase
Austin Weil
barney
Barry
Bert Hickman
Bill Kukowski
Blitzorn
Brandon Paradelas
Bruce Bowling
BubeeMike
Byong Park
Cesiumsponge
Chris F.
Chris Hooper
Corey Worthington
Derek Woodroffe
Dalus
Dan Strother
Daniel Davis
Daniel Uhrenholt
datasheetarchive
Dave Billington
Dave Marshall
David F.
Dennis Rogers
drelectrix
Dr. John Gudenas
Dr. Spark
E.TexasTesla
eastvoltresearch
Eirik Taylor
Erik Dyakov
Erlend^SE
Finn Hammer
Firebug24k
GalliumMan
Gary Peterson
George Slade
GhostNull
Gordon Mcknight
Graham Armitage
Grant
GreySoul
Henry H
IamSmooth
In memory of Leo Powning
Jacob Cash
James Howells
James Pawson
Jeff Greenfield
Jeff Thomas
Jesse Frost
Jim Mitchell
jlr134
Joe Mastroianni
John Forcina
John Oberg
John Willcutt
Jon Newcomb
klugesmith
Leslie Wright
Lutz Hoffman
Mads Barnkob
Martin King
Mats Karlsson
Matt Gibson
Matthew Guidry
mbd
Michael D'Angelo
Mikkel
mileswaldron
mister_rf
Neil Foster
Nick de Smith
Nick Soroka
nicklenorp
Nik
Norman Stanley
Patrick Coleman
Paul Brodie
Paul Jordan
Paul Montgomery
Ped
Peter Krogen
Peter Terren
PhilGood
Richard Feldman
Robert Bush
Royce Bailey
Scott Fusare
Scott Newman
smiffy
Stella
Steven Busic
Steve Conner
Steve Jones
Steve Ward
Sulaiman
Thomas Coyle
Thomas A. Wallace
Thomas W
Timo
Torch
Ulf Jonsson
vasil
Vaxian
vladi mazzilli
wastehl
Weston
William Kim
William N.
William Stehl
Wesley Venis
The aforementioned have contributed financially to the continuing triumph of 4hv.org. They are deserving of my most heartfelt thanks.
Registered Member #2292
Joined: Fri Aug 14 2009, 05:33PM
Location: The Wild West AKA Arizona
Posts: 795
HighVoltageChick wrote ...
... I had a problem with the 30awg. Don't use 30awg. Even for my coil (smaller than yours) its too thin, use 26. its easier (i have no jig either) and it has lot less resistance. foot per ohm, its about 10 feet. Too much. I also had a problem with the crosses and stuff. It's annoying, and with 30awg, sometimes you wind a section perfectly, then 4 inches up realize that there is a gap. I went through the trouble of making 2 and a half (first time the wire broke half way through, i was literally crying because I did nothing but that for hours straight) secondaries with 30awg, and they are all defective. I am soon to be getting 26awg, and I think you should too to save you the trouble I went through,
30AWG to thin?!?! HAHAHAHA Try working with 32 or 40 AWG then tell me it's to thin! Most of my DR secondaries are wound with 30AWG and it is not hard at all if you have a jig and a steady hand. The only coil I have that is anything larger than 30 is my 7 footer and it used 24AWG on it's massive 12x45 secondary.
Registered Member #3888
Joined: Sun May 15 2011, 09:50PM
Location: Erie, PA
Posts: 649
Eastern voltage research offers them, but they're a little more expensive than that. I think about half their price would be more reasonable.
Two common motors that will make decent winding jigs are microwave turntable motors and electric can opener geared motors. The turntable motor is a little slow, but it conveniently runs off of mains and slow and steady is better than fast and wire breaking. Tricky part is connecting your coilform holder to the axle of the motor. Set screws or epoxy puddy are simple solutions.
Smaller than 30awg is definitely doable. I recently did a 34 awg secondary by hand with no jig and didn't have any problems. Of course with higher power coils, the added secondary length of using thicker wire becomes important so that it's not constantly arcing to itself.
Registered Member #2288
Joined: Wed Aug 12 2009, 10:42PM
Location: Cambridge, MA
Posts: 179
I routinely wind 38 gauge secondary's on 1-2" PVC on a lathe in about 5 minutes, they come out flawless every time. Unfortunately the lathe I have access to is pretty small and impractical for coil winding over about 3", but any sturdy coil spinner should make winding any gauge trivial and fast with a little practice.
Aye, I almost plunked down the >$100 to have EasternVoltageResearch make my secondary, but I emailed about the manufacturing time and was told it was on the scale of weeks to months. I may be moving in a month so that took the option off the table for me.
It would be great if a competitor were to offer a coil winding service! For someone living out in the middle of no where like myself, it would be cheaper to have someone make a coil than to order in the tools and materials by freight needed to make a simple jig. If I do have to move though.. that is no longer a problem.
This site is powered by e107, which is released under the GNU GPL License. All work on this site, except where otherwise noted, is licensed under a Creative Commons Attribution-ShareAlike 2.5 License. By submitting any information to this site, you agree that anything submitted will be so licensed. Please read our Disclaimer and Policies page for information on your rights and responsibilities regarding this site.
Secondary Coil manufacturing flaw questions
