RE: [TCML] holding the ends of windings in place.

["Jim Mora" <wavetuner@xxxxxxxxx>]

Hi DC,

I knew you would jump in with Dolph's eventually. Thanks, you saved me a
search for which kind for my next secondary. I have had good success with
oil base Polyurethane though.

Jim Mora


-----Original Message-----
From: tesla-bounces@xxxxxxxxxx [mailto:tesla-bounces@xxxxxxxxxx] On Behalf
Of DC Cox
Sent: Friday, March 20, 2009 2:21 PM
To: Tesla Coil Mailing List
Subject: Re: [TCML] holding the ends of windings in place.

First, two coats of Dolph's AC-43 to cement the wires in place.

On the ends, I use a double layer of Teflon tape, 1 inch wide, on most all
of my magnet wire coils.  The windings are tightly cemented together with
Dolph's AC-43, which is especially design
for magnet wire.  It also have the very best creepage and dielectric
puncture rating of any insulation designed for this purpose.

After taping, I put the 3rd and 4th layers of AC-43 on the coil.  I sand
very lightly between each coat with 1,000 grit paper to remove any air
bubbles.

Dr. Resonance

On Fri, Mar 20, 2009 at 12:36 PM, Christoph Bohr <cb@xxxxxxxxxxxxxxx> wrote:

> Hello folks.
>
> Because someone asked me about this, I will try to
> clarify what I meant when speaking of another method of
> fastening the ends of winding.
> This better applies to transformes and chokes, less for
> secondaries.
> Pics would be much better, but I don't have any and won't
> be able to take some in the near future.
> Moreover, my english is not too good, but I will try my best,
> so, long story short, heres what you asked for:
>
> Start of winding:
> take a piece of adequate cloth 1/2inch wide and 1.5inches long.
> fold it around the wire so both ends point to one side, leave a
> sufficient length of wire for your connections to be made later.
>
> Additionally you might want to use some small hose or heat shrink
> tubing at the point where the wire goes through the V shaped cloth.
>
> Hold the wire and cloth against your core  / bobbin at the outer
> end with the long ends of the cloth pointing in the direction you are
> going to wind ( inwards ). Make the first turn so that the wire comes
> to rest upon the cloth. Make sure the wire is under good tension and
> finds its way close and parallel to the beginning  of the first turn.
> Continue winding and you will see, that the cloth will be firmly held in
> place under it.
>
>
> End of layer:
> About 15 or 20 turn from the end, start to wind over another piece of
> cloth.
> Same size but this time just flat on the core so it extends about half its
> length
> over the edge of the core. Then fold it over the winding and start to wind
> the
> next layer, which in turn will hold the strip in place.
> You can to this in several places around the diameter for extra stability.
>
>
> End of Winding:
> some distance from the end of the winding insert another
> v-shaped strip of cloth under the wire and wrap it to the core while
> winding. Wind until there is just a small lug of the cloth left. Big
> enought
> so that you can still get the wire through it but small enought to give
> a good hold. Run the wire through it and bend it to the opposite
direction.
>
>
> This is what I do and probably far from professional, but with a little
> practice it can give very tidy and stable windings without the use of
> a bobbin. Craft paper helps with stability.
> One example of a coil I wound using this method is this one:
> http://www.luebke-lands.de/pics/winding3.jpg
> These are 10K+ turns without bobbin and everything remains
> in place nicely...
> You can use some extra "wraps" at the beginning and end for it
> might hold the wire better in place, I don't but YMMV....
>
>
> hope this fields more questions that it rieses ;-)
>
> best regards
>
> Christoph Bohr
> _______________________________________________
> Tesla mailing list
> Tesla@xxxxxxxxxxxxxx
> http://www.pupman.com/mailman/listinfo/tesla
>
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