[TCML] Windings Repair - Should This Work? Is There a Better Way?

["Tedd Payne" <teddp2@xxxxxxxxxxx>]

Hi,

I'm trying to solve a problem with a spark coil, but maybe the solution could also benefit coilers in some way.

I've exposed a small section of the outer layer of the high voltage secondary winding.  The wire is very small, I can barely see the individual strands.  Here's the problem:  3 or 4 of the strands are broken and I'd like to repair them.  I'm not trying to reconnect individual broken pairs, I think it would be good enough to just "short" all the broken ends together.  I don't think I can use a blob of hot solder because I don't think I can adequately prepare the ends to bond to the solder, and I don't want to risk heat damage to the surrounding area.  Also, access to the wires is limited, kind of like in a hole.  I don't think I want to use a conductive paint or glue, because if it doesn't work then I may have made things worse by adding something which would be hard or impossible to remove.  Here's my idea:  use finely powdered silver or copper to try to fill the area around the breaks, maybe using a little liquid carrier which would evaporate cleanly.  My thought is that enough powder would allow electrical contact among all the broken ends.  If that works, then I would probably seal the repaired area in some way.

So, do you think the powder would work?  Do you have a better idea?

Thanks in advance for your comments!

Tedd
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