Re: Rolled cap hell ....easy

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

Original poster: "Dr. Resonance" <resonance-at-jvlnet-dot-com> 


Gary:

I presume you mean to say 6 mil poly and not .006 mil poly?

That would be a fit thin to handle with human hands.  Maxwell uses .5 mil
but it's machine wound and not touched by human hands.

Dr. Resonance



 >
 > 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?
 >  >
 >
 >
 >