A turn around the secondary coil. Again.

Hi everybody, not done a post for ages. Been busy with a bit of decorating and think I have not been looking forward to re-doing the secondary coil so have kept putting it off. I think it's time to finish the secondary so I can get on with testing and finally fire up this monster. Plus I think I need to move the Tesla to a safer area, at the moment it's in our freshly decorated living room which used to be pretty safe place where it wouldn't get damaged. Not anymore! Sadly we lost our old cat, Coco, a couple of months back but acquired 2 little rescue kittens, Milo and Lulu. They are mad. I haven't yet worked out if Perspex is claw proof and my Tesla looks like the worlds biggest scratching post.

If you want to see Milo and Lulu live take a gander at http://cats.damow.net from 10am till 4pm weekdays or anytime after 11pm any day. Live webcam of our kitchen (cats bedroom).

Anyway on with the Tesla. I have finalised the design for the windings on the secondary coil. The goal was to reduce the number of turns and this was achieved by increasing the diameter of the magnet wire on the secondary and reducing the length of the windings. I used JAVATC to generate the figures I needed.

With 1050 turns on the secondary resonance should be achieved by tapping the primary coil at turn number 11. The predicted resonant frequency is just over 180kHz and can be seen in the data below.

The new secondary coil blank is installed on my trusty winding jig. So glad I decided not to sell the jig on eBay after completing the first doomed secondary.

I made a small change to the winding jig. I replaced the original 148:1 motor/gearbox with a 50:1 unit. This should speed up the winding process, last time it took over 3 hours. The motor/gearbox units are produced by MFA and can be obtained from Maplin in a variety of ratios.

I have already purchased a few bottles of varnish to coat the coil after the windings are done. I am using the same as last time, it's made by a company called AEV (Advanced Electrical Varnishes) and is known as Ultimeg 2000/372 a high build Alkyd air drying anti-tracking varnish. The easiest place to get it is from Brocott on eBay but it's expensive in small amounts (£4.50 for 100ml plus p+p). You can also buy it from Hi-Wire Ltd for about £28 plus p+p but the smallest qty is 5 litres.

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Varnishing Secondary Coil

Have now had my secondary coil mounted in the winding jig for a couple of weeks. It seems to be taking ages to get the correct amount of anti tracking varnish on the coil. I have just applied the forth coat.

I have applied each coat by brush with the winding jig rotating at about 5rpm. It's a good way of holding the coil while its being varnished plus the rotation helps prevent runs from forming. As you can see after coat number 4 the coil seems to have a gloss finish. However on closer inspection.....

.....you can see there are still areas that have not been been completely covered by varnish. I have ordered another bottle of varnish which should give me another 2 layers which, hopefully, will give the full gloss cover over the whole coil.

I've noticed that you can still feel the individual turns in the areas that are not fully covered so I think I will use the rule that when it feels smooth it's got enough coats.