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Registered Member #611
Joined: Wed Mar 28 2007, 11:40PM
Location: Hudsonville, Michigan
Posts: 79
I finished winding my first coil last week. It's 4" pvc with about 20" wound with 26 gauge wire. It came out pretty nice, no loose turns or overlaps. The first few and last few turns are epoxied to the form. I left a few feet of wire off both ends. In the prossess of coating the coil with polyurethane, the lead wire that I left off the top turn broke from the stress of having to move it around to paint and sand around it. It broke right at the top turn. I carefully pulled about 1" of wire out of the epoxy off the top turn so I would have something to solder to.
Here's a picture of it on the turning rig. The blurry blue thing on the top is the extra wire rolled up and wrapped in masking tape. It broke off right at the epoxy on the top turn.
Can this be repaired with solder or should I wind a new coil?
Registered Member #162
Joined: Mon Feb 13 2006, 10:25AM
Location: United Kingdom
Posts: 3140
Certainly you can repair it, the 'trick' is to make it look like it was planned!
e.g. get the wire end in a solderable state, wrap around and solder to a length of pvc coated multistrand wire, embed the joint in epoxy to secure and hide it.
Registered Member #611
Joined: Wed Mar 28 2007, 11:40PM
Location: Hudsonville, Michigan
Posts: 79
Vaxian wrote ...
I had a similar thing happen to me, I just unwrapped 5 turns or so and left it at that.
I just looked at it and I don't think I'm going to be able to unwrap it. The wire is under 15 thick coats of polyurethane (I might have gone a bit overboard). It looks like I'm soldering it.
Sulaiman wrote ...
e.g. get the wire end in a solderable state, wrap around and solder to a length of pvc coated multistrand wire
Could you give me more details on what wire would be appropriate?
Registered Member #162
Joined: Mon Feb 13 2006, 10:25AM
Location: United Kingdom
Posts: 3140
ANY copper wire is suitable -should be at least same current capacity (mm2) as the coil wire -should look 'nice' -should be strong enough to handle/not break
You could use wire-wrap single-core or copper foil or almost any copper conductor.
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Secondary repair
