Problems with Information Unlimited transformer

["Tesla list" <tesla@xxxxxxxxxx>]

Original poster: Lkeen89@xxxxxxx 

I'm building the BTC3 Tesla coil from Information Unlimited, and tonight we 
did the first test run of the HV wiring. This step kinda pertains to my 
situation, so I'll cite it here:

20: Open up spark gap or place a piece of insulating material between 
electrodes to prevent firing. Verify proper assembly and plug unit into 
115VAC three wire grounded outlet. Check action of S1 (The main power 
switch), and note the neon indicator light lighting. (It did) Quickly short 
out the spark gap electrode attached to the capacitor to the chassis ground 
with the safety probe. Note a loud noisy bright discharge (It did.) Only do 
this momentarily, as it subjects the components to unusual stress, and only 
serves to verify proper operation up to this point.

(The actual primary/secondary coils were not attached.)
(The actual coils are not concerned in this problem. All talk about coils 
is referring to the transformer.)

Now, here's my problem: As soon as we flipped the switch, there was a bit 
of sparking inside the secondary of the transformer. We ran through the 
test as far as grounding it, and it worked just fine, except for the 
sparking in the transformer. We then shut everything down and attempted to 
ground the capacitor again to discharge it, to see if it had any residual 
charge. There was no spark. We were kinda concerned about the spark inside 
of the transformer, so we turned the coil on again and the transformer 
started to produce smoke, and there was an orange glow inside of the 
secondary of the transformer. We tried step 20 again, to ground the 
capacitor, but with no results. Are there any suggestions as to what might 
be the problem? I feel that there was an internal problem with the 
transformer, as we have gone through the wiring several times to verify its 
accuracy. The coil itself is due next week for a physics project. Could 
anyone provide any insight?      Thanks, Matt Keen.