[TCML] Secondary Damage (Large Coil)

[Amir Mojarradi <ln2guy42@xxxxxxx>]

Hello Everyone, 


My large secondary coil (12" diameter, 60" in winding length, 18 awg) has repeatedly exhibited overarcing at two specific points. A few months ago, I messaged the list, and decided to thickly re-varnish the damaged areas. 


Unfortunately, the problem has returned at the same two points. Since I am far away from the coil when I run it, I can not precisely determine the cause of the problem. From my research, I can infer two possible explanations. 


1. Insulation (varnish and wire enamel) is exposed and/or damaged; there is arcing between two turns of the coil. 
2. Insulation (varnish and wire enamel) is exposed and/or damaged; there is a premature breakout from a single turn of the coil. 


Below are pictures of the damage, to give a general idea. 


General Reference Image of the Secondary:
http://www.flickr.com/photos/teslalightning/7068998821/in/photostream/


Damage Point A:
http://www.flickr.com/photos/teslalightning/7068998895/in/photostream/


Damage Point B: 
http://www.flickr.com/photos/teslalightning/7068998945/in/photostream/


Normal Coil Performance: 
http://www.youtube.com/watch?v=yjChcjVm5ks


Any of these causes might necessitate a different solution. I am considering epoxying the damaged areas, using silver conductive epoxy to short out the arc, splicing the wires, or in the most extreme case, to re-wire the coil up to the damaged points and "surgically" soldering them. 


Would using a better insulating layer like Polyurethane or Epoxy help? What can I do besides re-wiring to solve this? 
Any related suggestions or comments will be extremely helpful, as any solution to this problem will require a meticulous undertaking.




Thank you for your helpfulness and dedication to the hobby of coiling, 


Amir Mojarradi 






 
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