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Registered Member #3806
Joined: Sat Apr 02 2011, 09:20PM
Location: France
Posts: 259
I finally finished my winding machine (very inspired from Terry Fritz's one - Thanks Terry for this nice doc!).
It allows winding of secondaries up to 70 cm long and 40 cm diameter.
It features: - variable speed from 8 to 150 rpm. - forward/reverse. - lap counter - foot switch
The motor is a 50:1 12V, it starts at 1V, giving a wide range of speeds. I used two plywood disks covered with hard rubber to hold and drive the coil.
I can finally start building my first two Tesla coils: 811A VTTC and EVR microBrute DRSSTC (You can see my 811A VTTC's secondary form installed on the machine)
Control Box
Reed switch and magnet for the counter.
Close view of the motor, reed switch, and the right coil holder.
Spool holder (Notice the spring which serves to slow the spool, and thus adjust the tension of the wire).
Registered Member #3806
Joined: Sat Apr 02 2011, 09:20PM
Location: France
Posts: 259
Winding my first secondary
This is a tiny secondary for my 811A VTTC. Winding is 15.5cm long with 480 turns of 0.3mm wire (~AWG 28).
Preparing:
First turns:
Close view thru the magnifying glass:
Almost done:
Coating with epoxy. I used Envirotex Lite coumpound with Herr Zapp's method. (Thanks Herr Zapp for the great tutorial).
Let cure for 8 hours with the winder running at low speed (~5rpm) (After 8-10 hours you can stop the motor, but wait 72h, hard cure time, before touching the coil)
Done - result is not perfect, but very close to, not bad for a first try The main problem I had was some dust floating in the air.
It's amazing how easy it is to wind secondaries using such a machine. A convenient winding speed for me was around 40 rpm.
Here are two tips I found really essential:
1) Have an adjustable "brake" on the spool holder, allowing a constant and suitable wire tension.
2) While winding, move the spool holder to keep an angle of 90 degrees less 5 to 10 degrees between the coil form and the wire.
Using these two tips you don't even need to guide the wire on the coilform, the winding is tight and there's no space between turns.
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My coil winder
