Re: [TCML] joining wires halfway through secondary winding

[Derek <tesla@xxxxxxxxxxxxxxxxxxxxxxxx>]

James,
    I had a similar problem when winding a coil, I pulled a birds-nest 
off the reel, had to break and join the wire.

    My Coil has been in use for 4+ years at 2x to 3x arc length 
compared to the secondary and I have never had any problems from the joint.

    I did much the same as you, as long as the joint is neat lays flat 
to the former and has a good covering of varnish you shouldn't have any 
problems.

     I'd aim for the joint to be nearer the top of the coil, the 
topload will give it some protection and it will be away from relatively 
earthy objects like the strike ring or primary.

Derek

On 01/04/2012 20:05, James Hutton wrote:
> Hey,I'm working on a 15kv 120ma nst tesla coil build using a 5.7inch pvc.The length of 26 gauge magnet wire needed for 25 inches of winding worked out to be just over 2,000 ft of wire.So to be safe, I bought 3,000ft.
> However, halfway through winding the wire ran out! I'm not sure if they sent me the wrong length of wire, or what happened, but I didn't have time to have more wire shipped and redo the winding. So I decided to join the wire with another spool of around 1,500ft 26 guage wire. I burned a few millimetres of enamel off each tip and connected them with solder. The joint was barely larger than the wire. Then I coated the solder joint with a bit of superglue, and dipped the wire in varnish and let dry several times. Then I wound the rest of the coil. I will be coating it many many times with varnish.
> I've heard that it is a really bad idea to join wire halfway through a secondary winding, but hopefully the job I did will hold up.
> Here are several pictures of the joining of the wires:
> -solder job: http://i40.tinypic.com/34zh89c.jpg-a few coats of varnish: http://i44.tinypic.com/243rkh4.jpg-The joint in the winding: http://i41.tinypic.com/zyg9yp.jpg-The full coil: http://i42.tinypic.com/w20q4l.jpg
> a few questions:Has anyone ever tried this before? and were there any problems?Should i have the joint closer to the top or the bottom of the coil?Any suggestions?
>
> thanks guys!
>
>
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