An update to my machine modification (coil winder)

[WolfeMacleod]

A while back I started modifying one of my machine to increase its output. Got it working, and stalled a bit because I needed a part. I proceeded to start a similar project with one of my other machines, stacking coils.

Woohoo! It's works! Machine modification

LEAKYSEALS951 asked if I would post a video when the rest of it was completed, so here it is. Need a bit of fine tuning though. I want to replace the first pulleys with very lightweight aluminum or nylon/delrin. The weight of the steel pulleys causes a very slight wobble to the winding face.
I think I'll add an idler pulley/ Eventually, I may try to something that doesn't add as much side pressure on the spindles... gear mechanism or something, I was warned about premature wear to the tailstock spindle.

[sc_rufctr]

Nicely done. That seems like a lot of wire on each coil.

Do you know how much in meters or yards is on each finished coil?

[LEAKYSEALS951]

That's insane. I had no idea how finely wound those things are. Thanks for posting!

[WolfeMacleod]

Originally Posted by sc_rufctr

Nicely done. That seems like a lot of wire on each coil.

Do you know how much in meters or yards is on each finished coil?

Depends.on the number.of turns, but it's generally.around 2000 feet.or more. That wire averages about 1700 ohms per 1000.feet. typical ohms on a coil is between 3.75k and 4.5k, depending on the model. On higher output stuff, up to 8000 turns of 43awg, so even more lenght.

[hawaiipcar]

Nice to see you got it working. Very cool..

Aloha
Ted

[Brando]

Can you show us creating a coil?

Very cool setup btw!

[t6dpilot]

Nice. Can you re-wind a couple of bobbins from an early 911 horn? I have three that are burned out and need to be rewound. Tough finding a source for that.

[WolfeMacleod]

Originally Posted by t6dpilot

Nice. Can you re-wind a couple of bobbins from an early 911 horn? I have three that are burned out and need to be rewound. Tough finding a source for that.

You know, there might be a possibility... upload a picture so I can see what they look like. If I can find out what gauge wire and how many turns, I don't see why not... as long as I can mount it.

Brando, watch the vid. Coils winding.

[t6dpilot]

Hey Wolf, I finally got some pics of the coils I need winded. You can clearly see the cause of the failure in the first pic. Moisture caused the E I laminations to corrode, which causes the coil to over heat when trying to magnetize them together. One of the wires leading to the power connections burned through. The other wire is fine and I can heat that connection to remove the bobbin and send to you if you want to give it a try. The wires are all intact and if you want me to determine the number of windings to save you time, I will do that and then send you it all with the bobbin. Dimensions are roughly 1.25 X 1.125 X .5 OD and .625 X .625 ID.

Let me know if you want to give it a try and I will send it to you. I would use a micrometer on the wire, but I do not have one here. I have two others that need winding and can send those along too if you think you can wind them. Really appreciate the help if you can!

[WolfeMacleod]

Originally Posted by t6dpilot

Hey Wolf, I finally got some pics of the coils I need winded. You can clearly see the cause of the failure in the first pic. Moisture caused the E I laminations to corrode, which causes the coil to over heat when trying to magnetize them together. One of the wires leading to the power connections burned through. The other wire is fine and I can heat that connection to remove the bobbin and send to you if you want to give it a try. The wires are all intact and if you want me to determine the number of windings to save you time, I will do that and then send you it all with the bobbin. Dimensions are roughly 1.25 X 1.125 X .5 OD and .625 X .625 ID.

Let me know if you want to give it a try and I will send it to you. I would use a micrometer on the wire, but I do not have one here. I have two others that need winding and can send those along too if you think you can wind them. Really appreciate the help if you can!

Why did I never see those before? Thanks for the PM!
That should be a piece of cake. In fact, it's small enough and few enough turns that it could be done completely by hand. I'm betting there's no more than a hundred or two hundred turns on each bobbin.

I'd have to check the size, and get a spool of matching wire...way bigger than what I normally use.

[t6dpilot]

Wolfe, checking back in... Sent you a PM. What do you say, shall we give this a try? I guess I could also try hand winding too. Not sure where to get that wire though.

[john walker's workshop]

I rewound a pair of coils from a 1950 cadillac convertible top solenoid valve by chucking up the bobbin in an electric drill clamped in a vise and hand feeding the wire. Worked great. Just need to keep the speed where you can control the wind.

[dad911]

I wouldn't worry about the tailstock. You don't need alot of belt tension with toothed belts/pulleys. Gears are going to be noisy.

[t6dpilot]

Where do you source the coil wire?