Tesla coil secondary winding jig
Kolas, Mon Jan 12 2015, 04:09PMI wanted to take a moment to share an idea that recently occurred to me and yielded great success.
If you're like me, finding a way to center and support the former is something of a challenge.
I wanted to find a simple and cheap way to support a 6" pvp pipe former. So after quite a bit of noodling it happened. How many of you have held a CF bulb over your head with a TC running? Well I had one of those "ding" moments.
Tires!
I found some tires that where about 1/4 too large when inflated. So I let the air out and forced one in on each side of the pipe and there it was, bearings and all. The outcome was a very well centered, strong, and smoothly turning jig!
A 1/2" x 6" long threaded rod is the axle. The belt goes directly around the pipe to allow "OMG" moment slippage.
I'm not sure if this has been done before but I would suggest it to anyone with a former 6" or larger.
While I would like to have built a guide for automated winding, my finger nails worked too. I eventually got confident enough to let the RPM's get over 100 and it got done fast. I think the best part is, I get to return all of these materials when I'm done.
If there was one thing I would change. It would be finding a way to have it not act so much like a van de graaff generator as I was constantly wiping dust and such off the former. (it was quite attracted to the pipe)
Any thoughts? Comments? Did one of you find an even simpler way?
If you like, use this idea and I hope it helps anyone struggling to do it another way.
Re: Tesla coil secondary winding jig
Graham Armitage, Mon Jan 12 2015, 08:31PM
Good suggestion - neat idea. What are those inflatable wheels from? I wonder if there are 4"inflatable wheels available.
I also had a thought about a using rubber cones inserted in each end - will center properly, can be used to drive the pipe rotation, and can accommodate different sized pipes. One cone could be driven and fixed to the bed, the other free-wheeling and on a slide for different length pipes.
I have wondered about having a grounded plate touching the pipe while spinning to reduce static. It is a hassle to keep cleaning it off.
Graham Armitage, Mon Jan 12 2015, 08:31PM
Good suggestion - neat idea. What are those inflatable wheels from? I wonder if there are 4"inflatable wheels available.
I also had a thought about a using rubber cones inserted in each end - will center properly, can be used to drive the pipe rotation, and can accommodate different sized pipes. One cone could be driven and fixed to the bed, the other free-wheeling and on a slide for different length pipes.
I have wondered about having a grounded plate touching the pipe while spinning to reduce static. It is a hassle to keep cleaning it off.
Re: Tesla coil secondary winding jig
Mads Barnkob, Tue Jan 13 2015, 08:20AM
You did also almost build a Van de Graff generator with a rubber belt on another plastic material with different electric properties.
I used a different approach, that is uni sizable to any pipe diameter, as the tubing is resting on top of two wheels in each end. I did also wind it at around 100 RPM and I would never waste my time to build a automatic guided winder, just holding the wire against the previous winding with a slight angle ensures a perfect alignment.
My rig:
Mads Barnkob, Tue Jan 13 2015, 08:20AM
You did also almost build a Van de Graff generator with a rubber belt on another plastic material with different electric properties.
I used a different approach, that is uni sizable to any pipe diameter, as the tubing is resting on top of two wheels in each end. I did also wind it at around 100 RPM and I would never waste my time to build a automatic guided winder, just holding the wire against the previous winding with a slight angle ensures a perfect alignment.
My rig:
Re: Tesla coil secondary winding jig
GrantX, Tue Jan 13 2015, 01:16PM
Here in Aussie-land there a lots of different sized small inflatable tires sold at hardware stores like Bunnings (I guess Harbor Freight and Home Depot are American equivalents). They're usually sold as lawnmower tires, or for mobile work tables and 'training wheels' for children's bicycles. Similar stuff like that. I'm certain you could find tires for any diameter secondary if you do some searching.
As for rubber cones, replacement ends for toilet plungers come to mind. There's probably a few other alternatives to be found, if you wander around a big hardware store for long enough.
As seen in another recent thread about static grounding issues, some metallic Christmas tinsel/garland and a earth connection could be beneficial.
This thread has inspired me think about turning my old discount 400W wood/plastic lathe into a small coil-winder. It can accept work pieces up to 1 meter long by 300mm diameter, but I'm unsure whether the cheap 400W motor will be enough.
GrantX, Tue Jan 13 2015, 01:16PM
Graham Armitage wrote ...
Good suggestion - neat idea. What are those inflatable wheels from? I wonder if there are 4"inflatable wheels available.
I also had a thought about a using rubber cones inserted in each end - will center properly, can be used to drive the pipe rotation, and can accommodate different sized pipes. One cone could be driven and fixed to the bed, the other free-wheeling and on a slide for different length pipes.
I have wondered about having a grounded plate touching the pipe while spinning to reduce static. It is a hassle to keep cleaning it off.
Good suggestion - neat idea. What are those inflatable wheels from? I wonder if there are 4"inflatable wheels available.
I also had a thought about a using rubber cones inserted in each end - will center properly, can be used to drive the pipe rotation, and can accommodate different sized pipes. One cone could be driven and fixed to the bed, the other free-wheeling and on a slide for different length pipes.
I have wondered about having a grounded plate touching the pipe while spinning to reduce static. It is a hassle to keep cleaning it off.
Here in Aussie-land there a lots of different sized small inflatable tires sold at hardware stores like Bunnings (I guess Harbor Freight and Home Depot are American equivalents). They're usually sold as lawnmower tires, or for mobile work tables and 'training wheels' for children's bicycles. Similar stuff like that. I'm certain you could find tires for any diameter secondary if you do some searching.
As for rubber cones, replacement ends for toilet plungers come to mind. There's probably a few other alternatives to be found, if you wander around a big hardware store for long enough.
As seen in another recent thread about static grounding issues, some metallic Christmas tinsel/garland and a earth connection could be beneficial.
This thread has inspired me think about turning my old discount 400W wood/plastic lathe into a small coil-winder. It can accept work pieces up to 1 meter long by 300mm diameter, but I'm unsure whether the cheap 400W motor will be enough.
Re: Tesla coil secondary winding jig
Kolas, Tue Jan 13 2015, 02:03PM
Hehe I'm glad you guys are running with this
I got my tires from Northern Tool and equipment. they are just mutli purpose utility tires. these were they smallest inflatable tires for about $11 USD. As far as the motor I used... It draws .75A at 120VDC 17in/lb and I only half wave rectified, so it only draws around 50 watts or so. I found that smooth high torque, low rpm was the way to go.
I have also done the two wheel support trick too (with k'nex, almost as good as duct tape) and I had moderate success, however when I would start to pull on it to get the wire tight, the former would attempt to jump off the jig.
Kolas, Tue Jan 13 2015, 02:03PM
Hehe I'm glad you guys are running with this
I got my tires from Northern Tool and equipment. they are just mutli purpose utility tires. these were they smallest inflatable tires for about $11 USD. As far as the motor I used... It draws .75A at 120VDC 17in/lb and I only half wave rectified, so it only draws around 50 watts or so. I found that smooth high torque, low rpm was the way to go.
I have also done the two wheel support trick too (with k'nex, almost as good as duct tape) and I had moderate success, however when I would start to pull on it to get the wire tight, the former would attempt to jump off the jig.
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