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Re: [TCML] Secondary Wire splice technique, gear reducer 4 sale
One word of caution regarding sources.
There is a lot of magnet wire floating around on E-Bay, and some at
attractive prices. A lot of this wire is factory seconds that have been
rejected for a variety of reasons --- small nicks, insulation thinness in
one area, failed hi-pot test, sometimes hidden splices or solder joints
hidden deep down in the rail which usually surfaces when your coil is about
75% wound, etc.
If you are on a tight budget, and building a smaller or medium size coil, or
a first "starter" coil, then, yes this is probably a good alternative.
If you are building a large coil, as Tyler is doing, then you may wish to
consider only a high quality factory tested double build magnet wire. Fay
is one distributor that I use all the time for my commercial coil winding
materials. The handle American Wire, Daburn, Essex, and other high quality
companies with excellent quality.
It takes a bit of time to prep and wind a large coil, then insulate it with
4-5 final coats.
Having one fail isn't much fun, so consider all options before grabbing the
best buy on E-Bay. I can say from experience I have had a lot of problems
with their IGBTs and now only use new ones.
On Sun, Jul 26, 2009 at 9:13 AM, Tyler Pauly <rpggod714@xxxxxxxxx> wrote:
> I can't help you on most of your questions, I don't have the experience or
> However, I did recently buy 25.3 lbs of 18 AWG high temp magnet wire for
> 240 dollars shipped, from Fay Electric.
> Also, the average electric drill isn't meant to run for too long.... I
> burnt one out already. So as of now I wind/spin by gloved hand.
> Took a long time to wind the 13.3"x60" coil...
> ----- Original Message ----
> From: Jim Mora <wavetuner@xxxxxxxxx>
> To: Tesla Coil Mailing List <tesla@xxxxxxxxxx>
> Sent: Sunday, July 26, 2009 4:24:46 AM
> Subject: [TCML] Secondary Wire splice technique, gear reducer 4 sale
> Hello Friends and Fellow Coilers,
> (1) I am preparing to wind nearly 22 pounds of #18 >200 degree wire. This
> available to me on 11 lb spools at near $100/ spool. Is this a good price?
> Can I get 22lb joined or bigger spool? I emailed Essex but they never
> emailed me back:-( I know how to silver solder a tapered splice which
> shouldn't be too hard with this size wire. My question is what to coat the
> splice with of very high dielectric coating properties? I want to keep the
> windings adjacent for ascetics.
> (2) I do plan on my usual few coats of polyurethane and may try my luck
> pour on 2 part epoxy (never tried before by me)...I can deal with drools!
> This is a ~7500VA coil. I guess I would want a slow cure product and of
> course constant turning. I would appreciate some experienced responses of
> conquered or failure mode hard knocks on these issues. What's a good pour
> product and application techniques? This is a new .125" thick 12.25" PVC
> former a big 5:1 ratio. It is getting a 56-60 x 12" top hat to shield the
> coil. I can give more design specifics if anyone is interested.
> I am building a mucho winder with a worm reduction gear box and an AC freq
> controller .5hz- 360hz near constant torque. It makes up to 3 hp 3 phase
> from single phase 240v, the next wind is a 22-24" sono tube. I'm using 2"
> thick wall hard conduit as the axle. The weather is hot and very dry this
> time of year in Ojai, Ca. - Good time to coat and wind!
> Thanks Much,
> Jim Mora
> For Sale:
> I have a smaller gear reducer .5" in (1/2" VS drill would be a great
> output 5/8" 13:1 ratio I believe it is 175 in-pounds of torque. It looks as
> new and turns freely with zero end play. I decided to go mongo (heavy duty)
> for the sono tube on the same rig. How does $30 sound? Just use a wide type
> fan belt on a 2"x 5/8" shaft alternator pulley and wrap the flat belt
> the end of the coil form. A used timing belt would work well too.
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