Building the Phase Shift Module

Hi there, it's been over a month since I last posted (blaming the purchase of a PS Vita). Haven't done anything with the tesla so you've not missed anything. Last post I did was about the 2 Amp variac purchased for phase shifting. I am still in phase shifting mode so I bought some perspex to house the new module.

The phase shift module will be housed in the perspex tube and will look similar in design to the tesla power source module I constructed. It will contain the 2 Amp variac and the 240v to 120v step down transformer that, at the moment, is mounted on the second level in the tesla base. This change in design is due to some advice I obtained from the very clever people at http://www.pupman.com. The advice was to step down the voltage to 120v before the phase shifting variac, hence the step down transformer will have to be external of the main tesla and it makes sense to house it within the new phase shift module.

Above is a pic of the present situ of the step down transformer. This will me removed and replaced by a module that houses the large capacitor needed in the phase shift circuit. Tonight I started on the housing for the new phase shift module. As usual the plastic was masked up ready for marking up and drill. The top and bottom of the housing will be held in place by 3mm allen bolts so first I marked up the holes needed.

I marked up both discs, then realised I could tape both discs together to drill at the same time. Both discs are 185mm diameter, the top disc is clear 8mm thick, the bottom is black and 5mm thick. I went for 8mm thick on the top as this disc will have the rather heavy 2 Amp variac bolted to it.

Here's both discs taped tightly together ready for drilling the 8 3mm clearing holes for the bolts.

Drilling went without any mishaps. If you want a few tips on drilling perspex take a look at my Drilling and Tapping Perspex page. The top disc needs an additional 10mm hole drilling dead centre to allow the variac shaft to pass through. After drilling this hole it was possible to rest the variac on top of the disc with the shaft passing through the hole to allow the marking of the four 6mm holes needed to mount the variac to the perspex disc.

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