[TCML] Re: Smallest gauge magnet wire for Secondary?

[<ConorPerry@xxxxxxxxxxx>]

Thanks for the info, I found this:

"Premium Quality 11LB Spool, 20 AWG, Essex Enameled Copper MW-35C Magnet 
Wire, High Temp. 200 Degree C"
http://www.magnet4less.com/product_info.php?cPath=9_20&products_id=190

They describe this as "heavy build" but I can't find a chart showing the 
diameters for Essex wire.  I did find it for MWS and they show a diameter of 
0.0346.

So for an 11lb spool, estimated at 3459 feet, on a 12" form only gives me 
1100 wraps on the secondary.  1100 wraps at 0.0346 gives a coil height of 
38", then 38"/12" gives an aspect ratio of 3.17:1 which is very low.

Do I buy more than an 11lb spool and splice?
Do I go with a larger gauge just to get more height and better ratio?
What are the negatives of going with a smaller gauge and doing space wound?

CP8071


----- Original Message ----- 
From: "DC Cox" <resonance@xxxxxxxxxxxx>
To: "Tesla Coil Mailing List" <tesla@xxxxxxxxxx>
Sent: Thursday, December 04, 2008 9:51 PM
Subject: Re: [TCML] Smallest gauge magnet wire for Secondary?


> Use the largest dia sec possible for max output.  If you use a 12" sec 
> coil,
> then 4.5:1 h/d produces a 54 inch winding length.
>
> Go up a bit from 1000 turns if possible.
>
> At 1,300 turns over 54 inches, then the math becomes:
>
> 54" winding length / 1,300 turns  =  .0415"  = 41.5 mils wire OD.
>
> Using double build sec insulation, the closet fit is 20 AWG double 
> insulated
> magnet wire.
>
> Top it off with a 24 x 5 or 30 x 8 inch dia toroid for high output.
>
> Dr. Resonance
>
>
>
>
>
> On Thu, Dec 4, 2008 at 6:03 PM, <ConorPerry@xxxxxxxxxxx> wrote:
>
> > Looking at the price of copper wire makes me dizzy.  I'd like to build a
> > 8"-12" secondary coil now.  When I work out the calculations for aspect
> > ratios for tight wound secondaries the copper size ends up between 19-22
> > gauge.  1000 wraps of a 8" diameter form is about 2100 feet, 12" diameter 
> > is
> > 3140 feet.  That's alot of copper!
> >
> > I'm not worried about the winding process, setting up a rotary encoder 
> > and
> > slave stepper motor won't be a problem.  So, ignoring easy to build tight
> > windings ... what's the smallest gauge that's realistic?
> > _______________________________________________
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