Re: [TCML] WINDING A FLYBACK

[Chip Atkinson <chip@xxxxxxxxxx>]

I've rewound one NST coil, ~10,200 turns of ~33 ga. wire.  It was years
ago so I don't have the exact numbers in my head.

I separated the layers with mylar drafting sheets and used cyanoacrylate
to hold the windings down to the mylar so they wouldn't fall off.  I don't
know about 28 ga. wire, but one of the problems that I had to solve was
that the wire would pile up on top of itself.  It wasn't thick and strong
enough that I could just pull it tight and have it lay flat.  I ended up
making a lead screw type mechanism which was basically a grooved piece of
metal that ran along a threaded rod which was connected by belts to the
winding shaft.  

IIRC, I did about 130 turns per layer which works out to about 78 layers.

Another problem that I had was that the form I wound on was the same size
as the core.  Unfortunately it was under tension so when I took it off the
form it sprung down a bit in size and no matter how badly I wanted it to
go on, I could not get my first effort on the core.   The second time
around I put a cardboard wrap around the form and it went on.

You should have seen the winder too.  Totally rube goldberg but it worked.

Chip

On Thu, 10 Nov 2011, Scott Bogard wrote:

> Greetings all,
>      Contemplating winding a few flybacks for high power operation (28 awg
> secondary) does anybody have any experience with this, I'm looking to make
> several identical ones for my plasma drivers, what should I use to separate
> the windings, paper, poly, mylar?  How may layers can I do?  What do I pot
> them in?  Google is turning up fairly little information, just wondered if
> anybody on list has tackled this, please note I am aware this will require
> patience...  Thanks in advance!  Oh and where can I get cores, I've found
> some on information unlimited but I've heard unsavory things about them,
> and am hesitant to order...
> 
> Scott Bogard.
> _______________________________________________
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> Tesla@xxxxxxxxxx
> http://www.pupman.com/mailman/listinfo/tesla
> 

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