RE: Rolled cap hell ....easy

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

Original poster: "Gary Weaver" <gary350-at-earthlink-dot-net> 

It is not as hard as it might seem.  I have rolled up several caps and I
had the same problem your having until I figured out how to do it.  First
of all cut your 2 aluminum plates and very carefully sand the edges smooth.
Cut your poly 2 times +16" longer than your aluminum plates and 4" wider.
If your aluminum plates are 10" x 48" then your poly needs to be 14" x 112"
long.  Place your poly on the floor in 2 equal stacks.  If your planning to
have 16 sheets of .006 mil poly between each aluminum plate then cut 8
sheet of poly 14" x 102" NOT 16 sheets.  Lay 8 sheets of poly on the floor
then place 1 aluminum plate at one end of the poly and fold the remaining
poly over the top of the aluminum so the aluminum is covered on both sides
with poly.   Do the same thing with your other aluminum plate.  Now place
the 2 stacks one on top of the other making sure the folded poly ends are
both on the same end of the stack.   Now you have 16 layers of poly between
each aluminum plate.  Place a 2x4 board on each side of the stick.  Roll up
both stacks of poly and aluminum on  a 1" pvc pipe.   As you roll slide the
2x4 boards along a few inches at a time to keep them out of your way.   The
boards will keep the poly from trying to slip to the side and get off
center while your roll up the capacitor.   Hold very tight all the time and
never let go.  When the cap is completely rolled up wrap it several times
with tape to hold it in place.  You can leave the 1" pvc pipe rolled up in
the middle or pull it out if you want it makes no difference.  Slide the
roll into a PVC pipe.  Attach the lead outs from the aluminum plates to
1/4" bolts or terminals screwed through the PVC end caps.   Be sure one end
cap has a hole drilled through it and tap the hole 1/8" NPT so you can
screw in a pipe cap later.  Glue the caps to the PVC pipe.  Attach a vacuum
pump to the 1/8" NPT hole and pump a vacuum.  Back fill the cap with high
voltage oil.  Screw a pipe plug into the hole to keep in the oil.  I make
all my caps rated 40,000. volts so they are bullet proof.  I have never
lost a cap and don't want to I have too much time invested in making it and
don't what to replace it.  If its done right the first time you will never
loose a cap.

Check out the pictures.

http://home.earthlink-dot-net/~gary350/cap1.jpg
http://home.earthlink-dot-net/~gary350/cap2.jpg
http://home.earthlink-dot-net/~gary350/cap3.jpg
http://home.earthlink-dot-net/~gary350/poly-c1.jpg
http://home.earthlink-dot-net/~gary350/tc10-4.jpg

Pic 1 my aluminum plates are 10" x 48" the tab is 1" x 9".  Fold the tab
over 90 degrees so it sticks out the side.
Poly is 8 sheets of .006 mil 14" x 112" long.

Pic 2 shows the poly folded over the top of the aluminum with the tabs
sticking out the sides.  Place one on top the other.  Start rolling from
the end that does not have the tabs.

Pic 3 shows the cap after it has been rolled up.

Pic 4 shows the finished cap.  .005 uf 40,000. volts.

Pic 5 shows the caps on my 10" coil.

Gary Weaver







 > [Original Message]
 > From: Tesla list <tesla-at-pupman-dot-com>
 > To: <tesla-at-pupman-dot-com>
 > Date: 10/22/2004 10:24:31 PM
 > Subject: Rolled cap hell
 >
 > Original poster: "Andrew Genseal" <aggniu-at-hotmail-dot-com>
 >
 > well, I attempted to roll my first cap tonight.  It was quite the
 > disapointment.  I have 6mil poly, and I am using the "sandwich" method (2
 > sandwiches with plates wrapped in 8 pieces of 66" long by 14" wide
 > poly).  The cap I am going for is roughly 003uF using 29" or 10" wide
roof
 > flashing for the plates (BTW, it is a simple 2 plate cap).  The enclosure
 > of choice is a 3" pvc pipe.  My biggest question is what is the best way
to
 > go about rolling these things up real tight? As a person who has never
 > attempted this before, I approached this thing thinking it would be
 > easy.....boy, was I wrong.  Is there any way of binding the sheets
 > temporarily to wind it, then removing such a device?
 >