Re: Attaching Toroid to Secondary

["Tesla list" <tesla-at-pupman-dot-com>]

Original poster: "by way of Terry Fritz <twftesla-at-qwest-dot-net>" <Parpp807-at-aol-dot-com>

In a message dated 11/26/01 9:58:02 PM Central Standard Time, 
tesla-at-pupman-dot-com writes:

<< The problem I see with this is that the height of the toroid won't be
 adustable, and I'm not sure how I'd attach the secondary wire.
  
 How do all you guys attach your toroids to your secondaries? >>

Hi Patrick,
I have tried several methods for this and all work fine.
First I would think of brass screws or threaded brass rod. 
10-32, 3/8, or 1/4 x 20 brass. You can cut a tapered plug (too difficult) or 
a disc from acrylic or Delrin. You can even use wood. The last three are easy 
to make. Drill a center hole for the mounting stud and then drill and tap 
four holes at a 90 degree spacing
to fasten the disk to the coil form. Use 6-32 nylon screws. Just putting an 
end cap
onto the coil form is OK but it may move the toroid out too far from the end 
of the coil.
You can cut down the end cap to maybe an inch. Use the flat caps, not the 
rounded.
Another arrangement that works well is to insert an end cap into the coil 
form. I use an
end cap one size smaller than the ID of the coil form. Drill the center hole 
for the mounting
stud and insert the end cap so the top of the cap is flush with the end of 
the coil form.
Then drill and tap the four 6-32 screw holes to hold the end cap in place. 
This arrangement is very nice when you want the toroid as close to the 
winding end as possible. Some will say it's a no no but I drill one or two 
very small holes at the coil end 
to anchor the lead. Bring the lead to the outside of the end cap, clean the 
end of the wire and wrap it around the mounting stud
under a brass washer and then tighten down with a nut to hold the stud to the 
end piece.
Toroid height is easily adjusted with a nut and washer combo.

Happy day,
Ralph Zekelman