Re: [TCML] Secondary Damage (Large Coil)

[Bert Hickman <bert.hickman@xxxxxxxxxx>]

Hi Amir,

Many coilers have had excellent results using Envirotex Lite Pour On 
High Gloss Finish. This two-part resin is available in many craft and 
hardware stores and it can also be ordered through numerous online 
sources.

http://eti-usa.com/envirotex-lite/
http://eti-usa.com/wp-content/uploads/2011/03/Envirotex-Lite-English-Instruction-Sheet1.pdf

You'll need to set up a well-ventilated, but dust-free (and flying 
bug-free!) work area. You will also need to set up a fixture that can 
continually rotate the coil form at a surface velocity of ~4 - 5 
inches/second. You'll want to apply a relatively thick final coating 
(1/16"  - 1/8" max). You'll need apply the resin within ~25 minutes or 
less after mixing. You'll need to continuously rotate your secondary 
while applying the resin, and then continue rotation until the resin has 
sufficiently hardened (typically 6-8 hours) to prevent sagging. Some 
excellent practical information can be found in the TCML Archives. Look 
for the "Envirotex Lite , High Torque drive" thread in the July, 2009 
archives.

When done right, you'll get a beautiful, hard, crystal-clear coating 
that completely imbeds and protects the entire winding. Be sure to allow 
your coating to completely harden (2-3 days) before using it in your 
system.

Good luck,

Bert

Amir Mojarradi wrote:
> Hi Bert,
>
>
> Thanks for your helpful advice. Is there a particular brand or type
> of epoxy or polyester that you recommend? I know other forms of epoxy
> exist, but the only products I have seen at major hardware store are
> the small,  "5 min" epoxy tubes. Would these be sufficient?
>
>
> Thank You,
>
>
> Amir Mojarradi
>
>
>
> -----Original Message----- From: Bert
> Hickman<bert.hickman@xxxxxxxxxx> To: Tesla Coil Mailing
> List<tesla@xxxxxxxxxx> Sent: Thu, Apr 12, 2012 8:18 am Subject: Re:
> [TCML] Secondary Damage (Large Coil)
>
>
> Hi Amir,
>
> The insulation between turns has been damaged, possibly by a strike
> to the winding, an arc-over from the primary to the lower part of
> the secondary, or by handling. Strikes to the secondary can be quite
> damaging on larger coils such as yours. At the very least you'll need
> to remove the windings around the affected areas, or remove the
> bottom portion of the winding since the coil form may now also be
> carbonized underneath.
>
> Once the winding has been removed from the affected areas,
> scrape/sand away any traces of carbonization from the form before
> applying new wire. Once you have repaired the winding, you may also
> want to consider applying a thick 2-part polyester or epoxy coating
> over the winding. This will protect it mechanically as well as
> helping to prevent any future damage if you get another strike to the
> secondary. The strike will harmlessly spread out along the surface of
> the coating instead of destroying the insulation/wire at a single
> concentrated point.
>
> Bert



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