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Re: Rolled cap hell ....easy
Original poster: "Gary Weaver" <gary350-at-earthlink-dot-net>
I know what your saying about the poly sliding around and getting uneven
and out of line. The stuff is slippery and almost impossible to roll up.
That is why I came up with the idea of folding the poly over in the middle
it solves the problem of sliding. I use a small amount of tape on my caps
but I worry about using a lot of tape. The oil will disolve the glue on
the tape and the glue will become part of the oil. A small amount of tape
does not seem to be a problem. I used masking tape on my caps. Lay the
1" pvc pipe on the poly and fold the poly ends and aluminum plates around
the pipe. Hold it very tight and start rolling. You will find this is 50
times easier than trying to roll up several cut sheets of poly where the
ends have all been cut off and are not folded around the plates.
If you have already cut your poly and don't want to waste it then make some
new aluminum plates so you can use the poly that you have already cut.
You can roll up 2 or 3 seperate capacitors one on top the other then
connect them in parallel inside the case. If you are having a problem
rolling up a 4 ft long aluminum plate then cut it in half so the plates are
2 ft long. Its a lot easier to roll up a short plate than a long one but
you have to do it twice to keep the UF or MFD value you want. Roll up the
first cap and rap some tape around it to hold it in place then roll the
second cap right over the top of the first one. Connect the tabs in
parallel at the terminals inside the case.
Aluminum foil is much harder to roll up than aluminum flashing in some
cases it depends on the cap size. I have rolled up as many as 4 seperate
caps one on top the other. Connect all 4 caps in parallel and it works
fine. My aluminum foil was 3" wide 12" long. I rolled up 4 seperate caps
one on top the other then connected them in parallel. This was a low
voltage cap compaired to my others as I recall it was 10KV for a small 6K
20ma transformer.
Gary Weaver
> [Original Message]
> From: Tesla list <tesla-at-pupman-dot-com>
> To: <tesla-at-pupman-dot-com>
> Date: 10/25/2004 6:13:02 PM
> Subject: Re: Rolled cap hell ....easy
>
> Original poster: "Andrew Genseal" <aggniu-at-hotmail-dot-com>
>
> Thanks for the advice. Actually, I have been reading just about
everyones
> sites on building these things and I have had some thoughts. First,
nobody
> seemed to address what happens when you start to roll the thing, you
can't
> get a good grip on the entire roll and the sheets slip on themselves.
The
> only solution that I found to sort of work was to loosly roll the thing
up,
> then twist the inside end of the sheet while grasping the entire
cylinder.
> Then, I read someones site on how they went about solving this, they took
a
> piece of 3/4" cpvc and slit it lengthwise. Then, they used hose clamps
> around the slit tube to make a clamp to grip the poly and plate
> sandwich. I think that this may solve my and most everyone elses
problems
> with these things. One more question that I have is, can some small
pieces
> of duct tape be used to line up the Al plate at the beginning of the roll
> before it would be gripped by the slit cpvc to keep it from sliding out
of
> position? Any thoughts or opinions on this would be helpful, especially
if
> anyone has tried something like this before.
> ----- Original Message ----- From: "Tesla list" <tesla-at-pupman-dot-com>
> To: <tesla-at-pupman-dot-com>
> Sent: Sunday, October 24, 2004 6:35 AM
> Subject: RE: Rolled cap hell ....easy
>
>
> >Original poster: "Gary Weaver" <gary350-at-earthlink-dot-net>
> >It is not as hard as it might seem. I have rolled up several caps and I
> >had the same problem your having until I figured out how to do it. First
> >of all cut your 2 aluminum plates and very carefully sand the edges
smooth.
> >Cut your poly 2 times +16" longer than your aluminum plates and 4" wider.
> >If your aluminum plates are 10" x 48" then your poly needs to be 14" x
112"
> >long. Place your poly on the floor in 2 equal stacks. If your planning
to
> >have 16 sheets of .006 mil poly between each aluminum plate then cut 8
> >sheet of poly 14" x 102" NOT 16 sheets. Lay 8 sheets of poly on the
floor
> >then place 1 aluminum plate at one end of the poly and fold the remaining
> >poly over the top of the aluminum so the aluminum is covered on both
sides
> >with poly. Do the same thing with your other aluminum plate. Now place
> >the 2 stacks one on top of the other making sure the folded poly ends are
> >both on the same end of the stack. Now you have 16 layers of poly
between
> >each aluminum plate. Place a 2x4 board on each side of the stick. Roll
up
> >both stacks of poly and aluminum on a 1" pvc pipe. As you roll slide
the
> >2x4 boards along a few inches at a time to keep them out of your way. The
> >boards will keep the poly from trying to slip to the side and get off
> >center while your roll up the capacitor. Hold very tight all the time
and
> >never let go. When the cap is completely rolled up wrap it several times
> >with tape to hold it in place. You can leave the 1" pvc pipe rolled up
in
> >the middle or pull it out if you want it makes no difference. Slide the
> >roll into a PVC pipe. Attach the lead outs from the aluminum plates to
> >1/4" bolts or terminals screwed through the PVC end caps. Be sure one
end
> >cap has a hole drilled through it and tap the hole 1/8" NPT so you can
> >screw in a pipe cap later. Glue the caps to the PVC pipe. Attach a
vacuum
> >pump to the 1/8" NPT hole and pump a vacuum. Back fill the cap with high
> >voltage oil. Screw a pipe plug into the hole to keep in the oil. I make
> >all my caps rated 40,000. volts so they are bullet proof. I have never
> >lost a cap and don't want to I have too much time invested in making it
and
> >don't what to replace it. If its done right the first time you will
never
> >loose a cap.
> >
> >Check out the pictures.
> >
> >http://home.earthlink-dot-net/~gary350/cap1.jpg
> >http://home.earthlink-dot-net/~gary350/cap2.jpg
> >http://home.earthlink-dot-net/~gary350/cap3.jpg
> >http://home.earthlink-dot-net/~gary350/poly-c1.jpg
> >http://home.earthlink-dot-net/~gary350/tc10-4.jpg
> >
> >Pic 1 my aluminum plates are 10" x 48" the tab is 1" x 9". Fold the tab
> >over 90 degrees so it sticks out the side.
> >Poly is 8 sheets of .006 mil 14" x 112" long.
> >
> >Pic 2 shows the poly folded over the top of the aluminum with the tabs
> >sticking out the sides. Place one on top the other. Start rolling from
> >the end that does not have the tabs.
> >
> >Pic 3 shows the cap after it has been rolled up.
> >
> >Pic 4 shows the finished cap. .005 uf 40,000. volts.
> >
> >Pic 5 shows the caps on my 10" coil.
> >
> >Gary Weaver
> >
> >
> >
> >
> >
> >
> >
> > > [Original Message]
> > > From: Tesla list <tesla-at-pupman-dot-com>
> > > To: <tesla-at-pupman-dot-com>
> > > Date: 10/22/2004 10:24:31 PM
> > > Subject: Rolled cap hell
> > >
> > > Original poster: "Andrew Genseal" <aggniu-at-hotmail-dot-com>
> > >
> > > well, I attempted to roll my first cap tonight. It was quite the
> > > disapointment. I have 6mil poly, and I am using the "sandwich"
method > (2
> > > sandwiches with plates wrapped in 8 pieces of 66" long by 14" wide
> > > poly). The cap I am going for is roughly 003uF using 29" or 10" wide
> >roof
> > > flashing for the plates (BTW, it is a simple 2 plate cap). The >
enclosure
> > > of choice is a 3" pvc pipe. My biggest question is what is the best
way
> >to
> > > go about rolling these things up real tight? As a person who has never
> > > attempted this before, I approached this thing thinking it would be
> > > easy.....boy, was I wrong. Is there any way of binding the sheets
> > > temporarily to wind it, then removing such a device?
> > >
> >
> >
>
>