Re: [TCML] Secondary Damage (Large Coil)

[jhowson4@xxxxxxxxxxx]

I think you are a little off 

1). Remove bottom winding (~250 turns) - up until the damaged points. 
(If you want to, as it "May" have carbonization underneath, but just effected turns is a minimum) 
2). Sand/scrape off the carbonized damage on the coil form 
3). Apply thick epoxy resin coat onto the coil form 
(I think this step is wrong, you want to wind your new wire on the same level at the old wire, minus a little sanding. Ie no epoxy layer. at least what i would do anyway) 
4). Splice in a new wire 
(try and keep it as lat as possible, their are a couple techniques which can be used, i would just pay the new wire next to the old one and solder them together to ensure a good connection, maybe someone else can comment on this) 
5). Wind new bottom winding 
(or just the missing windings) 
6). Apply thick epoxy resin coat onto the new winding. 
(I highly recommend the epoxy, but only if you have speed controlled jig to rotate the whole coil, this is the way to go. I made my first epoxy coated secondary over the summer, and I will never go back to varnish. Yes you should coat the whole secondary over the existing varnish. Its like adding a 1/16" layer of indestructible glass over the whole thing. Very durable, and it looks fantastic http://i139.photobucket.com/albums/q295/JHowson/IMAG0253.jpg ) 



Thanks, 
John "Jay" Howson IV 


"Why thank you, I will be happy to take those electrons off your hands." 

----- Original Message -----
From: "Amir Mojarradi" <ln2guy42@xxxxxxx> 
To: tesla@xxxxxxxxxx 
Sent: Friday, April 13, 2012 4:49:16 PM 
Subject: Re: [TCML] Secondary Damage (Large Coil) 

Hi Bert, 


That sounds fantastic. 


Based off of your information, I have a clear idea of the necessary steps I will take: 


1). Remove bottom winding (~250 turns) - up until the damaged points. 
2). Sand/scrape off the carbonized damage on the coil form 
3). Apply thick epoxy resin coat onto the coil form 
4). Splice in a new wire 
5). Wind new bottom winding 
6). Apply thick epoxy resin coat onto the new winding. 


Sound all right? 
Would you recommend applying the Envirotex over the entire coil, even parts which are already coated with several layers of varnish? 


I'll keep you updated about how the procedure goes. 


Thank you for your kindness, 


Amir Mojarradi 




-----Original Message----- 
From: Bert Hickman <bert.hickman@xxxxxxxxxx> 
To: Tesla Coil Mailing List <tesla@xxxxxxxxxx> 
Sent: Thu, Apr 12, 2012 7:47 pm 
Subject: Re: [TCML] Secondary Damage (Large Coil) 


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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