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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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