Re: [TCML] WINDING A FLYBACK

[Scott Bogard <sdbogard@xxxxxxxxx>]

Hi Time,
     From what I can tell Mylar is the material of choice for the
discerning flyback builder, but I'm not sure where to find a 1-in wide roll
of it, so I'll probably stick to the teflon.  Trouble will be holding the
thing together since teflon by nature is slippery.  Perhaps there is a
cheap epoxy I can saturate paper with to hold the layers together...

Scott Bogard.

On Wed, Nov 23, 2011 at 9:20 AM, Tim S <stm800@xxxxxxxxxxx> wrote:

> I did a test a couple of years ago with silver anti static bag material.
> 2 inch round copper disks like a spark gap and placed a single sheet of
> anti static bag material in between,the material was slightly bigger
> diameter than the disks.
> Then adjusted the all thread rod to sandwich the plates together tightly
> and ramped up the voltage to 10 kv @ 30~45 khz with a solid state driver.
> blue corona was seen in the dark but no arc through occurred.
> some one else might want to try it and post more results.
>
> Happy Holidays All.
>
> Tim
>
> --- On Wed, 11/23/11, Adam <teravolt.org@xxxxxxxxx> wrote:
>
> From: Adam <teravolt.org@xxxxxxxxx>
> Subject: Re: [TCML] WINDING A FLYBACK
> To: "Tesla Coil Mailing List" <tesla@xxxxxxxxxx>
> Date: Wednesday, November 23, 2011, 2:58 AM
>
> I'm not so sure rubber cement would be a good insulator. I used teflon tape
> because it is very plastic, and when pulled tightly it for the most part
> conformed to the windings and squeezed air out.
>
> As for rosin, use a 50 50 mix of beeswax and rosin. That's what they used
> to use in the 40s for insulation, and it works well. Doesn't shrink on
> cooling and it's nice and plastic.
>
> http://imgur.com/a/OPw3U
>
> On Tue, Nov 22, 2011 at 7:25 PM, Scott Bogard <sdbogard@xxxxxxxxx> wrote:
>
> > Yeah I think I'm going to avoid potting it, as much as that will give a
> > better product, to build a vacuum machine to do it properly, I think I'll
> > try other routes.  I'm thinking the rubber cement and paper will be a
> good
> > idea, should be voltage resistant, and I can coat the wire with fresh
> > cement as I wind it, ensuring no air underneath.  Than again the idea of
> > using rosin is good as well, and will be less likely to break down over
> > time, and require less heat than wax, so as not to damage the teflon.  I
> > think I'm going to have to try some things, if I have more questions I'll
> > be sure to send them your way.
> >
> > Scott Bogard.
> >
> > On 11/22/2011 3:15 PM, Adam wrote:
> >
> >> Don't use parrafin. The problem I've encountered with that is its
> massive
> >> shrinkage when it cools, which leads to cracks and air bubbles. Instead
> >> use
> >> beeswax, or a mixture of rosin and beeswax. It doesn't shrink nearly as
> >> much.
> >>
> >> http://i.imgur.com/UOQ5U.jpg
> >>
> >> As for leading the wire thru, I just put the next layer of tape 'under'
> >> the
> >> wire, so it's just a continuous spiral.
> >>
> >> On Tue, Nov 22, 2011 at 12:37 PM, Scott Bogard<sdbogard@xxxxxxxxx>
> >>  wrote:
> >>
> >>  Hi Adam,
> >>>     That is impressive, not exactly what I was looking for but
> impressive
> >>> nonetheless, elegant in its simplicity even.  My only concerns are
> thus,
> >>> the presence of air between windings since it is not technically potted
> >>> (which could be rectified easily by swapping out the electrical tape
> with
> >>> some kind of paper, and then potting in paraffin or epoxy, as long as
> it
> >>> does not get too hot to melt the Teflon) and how long it took to build
> >>> (25
> >>> hours, ugh...)  I am planning on making a number of flybacks, so I will
> >>> have to find a way to expedite the process, even if it is just mounting
> >>> it
> >>> on a rotating rod.  You have given me much to think about, thanks very
> >>> much
> >>> for sharing, I'm thinking maybe I will do this with paper coated in
> >>> rubber
> >>> cement (which shouldn't melt Teflon, and provide decent dielectric
> >>> shielding) I'll probably have to make one layer at a time, since it
> won't
> >>> stick to itself, but should make a fairly rigid finished product,  How
> do
> >>> you do the lead through from one layer to another?  Just leave the wire
> >>> sticking out until you put down your tape then bring it over?
> >>>
> >>> Scott Bogard.
> >>>
> >>> On Mon, Nov 21, 2011 at 6:31 PM, Adam<teravolt.org@xxxxxxxxx>  wrote:
> >>>
> >>>  Not sure if I'm doing this right....
> >>>>
> >>>> But this might help you somewhat http://teravolt.org/fryback.**php<
> http://teravolt.org/fryback.php>.
> >>>> It's
> >>>>
> >>> my
> >>>
> >>>> results at making an FBT.
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