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Winding technique

Original poster: "Dr. Resonance" <resonance@xxxxxxxxxx>

One interesting trick large commercial xmfr winders use is to route the
enameled magnet wire through a simple piece of cardboard in a "V" shape.  A
small lightweight clamp allows different tension on the cardboard V
depending on the gauge of wire being wound.  It was amazingly simple but
they used this technique on over 20 winders all hard at work winding pole

The magnet wire is located on a simple dowel type arrangement and is located
down near the floor.  The V cardboard is up on a metal stand at a level even
with the xmfr being wound.  The magnet wire makes a approx 70 degree bend at
the cardboard V.

The engineer told me they have used this technique for over 40 years!
Simple but effective.

We use a similar arrangement with our lathe.

Dr. Resonance
 >  >
 >  > I have a set up to make coils from 1" to 15"
 >  > diameter up to about 5ft long.
 >  > How many coils do you want.  I make a few coils from
 >  > time to time and sell
 >  > them on ebay mostly because it helps out the hobby
 >  > the secondary coils take
 >  > a long time to wind by hand.
 > Well, I am happy that you are helping out the hobby,
 > but I have to differ with you on the contention that
 > secondary coils take a long time to wind by hand.  If
 > you have a wife or partner to help, it can be knocked
 > out in a hurry.  I wound my 6" dia 24" long secondary
 > with a temporary jig set up between two collapsable
 > aluminum saw horses.  I had a cheap wooden dowel as
 > the shaft for the spool of magnet wire, and endcaps
 > with carriage bolt axles in the center for the coil
 > former.  After using masking tape to secure the wire,
 > I spun the form with both hands while my wife kept the
 > rate of spin on the spool constant as well as guiding
 > the angle of the wire.  I was also making sure the
 > wire was tight and flush before putting a piece of
 > temporary tape over each new few inches of winding.
 > We knocked out the whole job in just 45 minutes!
 > Perfect secondary, no overlaps, kinks, gaps or
 > problems at all.  I have also wound others since then
 > with equal success.  The great thing too, is that you
 > can start applying coats of polyurethane (or whatever)
 > while the coil is still sitting the the jig.  Then
 > after you are done, you can just untape the axles and
 > everything and collapse the sawhorses and store them
 > away for later.  I used aluminum tape for the axles,
 > since it has a much stronger adhesive.
 > -Brett
 >  > I might be
 >  > interested in making you some
 >  > coils.  I can get any size enamel coated copper wire
 >  > it comes in 100 lb
 >  > rolls.  Tell me what you need.
 >  >
 >  > Gary Weaver