I applaud you working on this. I’ve always been interested in coil winding and your initiative, combined with the constructive comments, is moving the body of readily available public knowledge forward!

I would suggest mounting your coil much further away so that the angle as it unwinds is much more uniform. Also turning it vertical so that the horizontal position on the spool changes less would help with a more accurate feed.

@jtkilroy

4 жыл бұрын

I agree, I can make the 90 degree change with very few mods to the setup.

Having run coil winders in my youth, a few suggestions: 1. You need a smooth bobbin. You figured the rough cut was causing you problems, and you are right. 2. If you are going to use a guide, put it about 4" to 6" back from the coil, not as close as you have it. 3. Unless you deliberately want a spaced lay, get the feed as close as possible to the wire diameter. Don't forget the insulation thickness. 4. Get some 1/4" or 1/2" kynar tape rather than electrical tape. 5. The way you tape the entry wire is to cut a piece of tape about 2" longer than the width of the wind on the bobbin. Holding the tape horizontal and face down, stick the wire to the tape about an inch from the end of the tape and fold the tape back on itself. Now lay the tape down across the full bobbin width, with the loop at the right edge, then bend the loose end to the right. I'd stick the end to the bobbin with a small of tape to keep it from flapping around. This gives the wire a straight feed in to the winding, and the winding is going to hold the tape down as a strain relief on the entry wire.

@jtkilroy

4 жыл бұрын

Thanks a bunch for the knowledge of your experience. Information like this is GOLD!

Great presentation James, a very cool process to watch, and I love all the tweaking suggestions. Maybe down the road you could give a removal and processing video to show what the coils look like in the end, thanks and cheers!

I suppose everybody already mentioned the tensioner wingnut tightening itself, maybe some fischpaper on the drum of the winder. You're right about it beating the hell out of hand winding,that was always a super pain. Whenever I watch you always inspire me to new projects. Thanks next time you're in Pensacola stop by.

You may want to check the wire for signs of insulation scraping or damage. A nylon or plastic rod with an .040 hole instead of the mig tip might be better on the wire. Also try bending a metal bracket to hold the tip. Much stiffer than a piece of wire.

@jtkilroy

4 жыл бұрын

I'll do that, thanks for the tip.

I made a steel mount for my mig tip . It needs to be mounted solid so it will follow the feed of the lathe. Someone else said what ever you are winding it on needs to be smooth and needs edges and he is right. You need to get the feed of the lathe right to the size of the wire,Hope you get it, it is a challenge. Good luck

Well it is kind of working. I think there are some good suggestions in the comments. Reversing backlash is a killer and causes a pile of wire, and a more square edge to come to would help reverse the wire quicker. I would think a more rigid wire feeding setup with more tension would be better, Heavy music wire 3/16" maybe. Just my thoughts, Thanks James for sharing the path.

@lwilton

4 жыл бұрын

If you don't have an edge to reverse against, stop at the edge, put a loop of tape around the wire and tape it outside the lay, then start the reverse lay.

Suggestion put a Teflon locknut and a washer on the thread side of your spring that will stop it from getting tighter then you want. As you see when the spool is turning the spring is making the wing nut get tighter. I think you get my idea lol

@jtkilroy

4 жыл бұрын

No doubt, and I probably have those parts in my inventory.

If you want to space the turns a little to match the lathe feed you might try spraying the pipe with a light coat of contact adhesive like 3M 77 to help fix the wire in place.

@jtkilroy

4 жыл бұрын

That is a great idea, thanks. Next time I make one I'll give it a try.

Looking good. Couldn't help but notice the tensioning wing nut was tightening itself, might lead to a problem down the line. ATB c

@jtkilroy

4 жыл бұрын

I've got a washer on there now, helps a lot.

@paulwomack5866

4 жыл бұрын

I came to this comment section to say exactly that!

That was quick

I would use a thread pitch if applicable. 80tpi is 0.0125.

@jtkilroy

4 жыл бұрын

I think you are right. I was trying for a more spaced out coil. They don't have to be tight, from past experience. But I am going to try that next, along with several other suggestions by some of the other viewers.

I found the best way for me was to work out the nearest thread pitch for what you are winding then set feeds and speeds to suit. Also you need quite a lot of tension on the wire.

at 6:13 it sure looks like the Mig tip is pealing the varnish off the wire.. i have not reached the end of the video.. you may want to twist the mig tip so the wire coming off the roll goes straight thru the tip and does not change angle.. i will watch the rest tomorrow night.. falling off my chair i am so sleepy.. my aunt used to wind coils for rayetheon. when she retired after 45 or 50 years.. they begged her to come in one or two days a week to wind the most important coils.. she used her long fingernail with a groove in the end to wind it perfectly.. another friend did the same for Leach relays. he actually had a placard from the neil armstrong and others for when they examined a few of the relays he produced .. they were perfect. he used his fingernail also.

@jtkilroy

4 жыл бұрын

Shit if you are not right, great catch. I am going to test that coil in the morning, make sure its not shorted. Might get another chance to wind this coil sooner rather than later.

@waynep343

4 жыл бұрын

@@jtkilroy use Nylon tubing as a guide.. or teflon tubing as a guide... even HDPE..

@waynep343

4 жыл бұрын

@@jtkilroy kapton tape also.. not electrical tape

killroy, try drilling a hole thru the piece you tension/wingnut rides on. you can simply slide a nail through it to stop the wingnut from continually loosening as your winding.

Cool video do you think you could put the Mig tip in a indicator holder

@jtkilroy

4 жыл бұрын

That is a great idea. I could turn a little bushing to hold it in a Noga.

A piece of Delrin with a proper sized hole might be better than the nozzle which could wear off the insulation on the wire. A 9/64 inch or 3.6 mm hole would just accept the 28 gauge wire.

Your getting that coil winding down pat a few adjustments and you will have it

Like the video! But what are the coils you making used for?

@jtkilroy

4 жыл бұрын

Proximity switch

@ypop417

4 жыл бұрын

@@jtkilroy That's one Big Proximity Switch

@jtkilroy

4 жыл бұрын

@@ypop417 An instrument cable and instrument of about 4" dia. run through the pipe. A 3" diameter iron ball is attached to the cable and the proximity switch detects the ball, on the move and triggers an input on a motor controller.

mr kilroy why do you want coils like this? im new to your channel. are you into tesla coils?

@jtkilroy

4 жыл бұрын

Its for an inductive proximity switch.

@andym5195

4 жыл бұрын

i dont know what that is but i think i need one!! dude its a great set up there, you could make awesome tesla coils though :)

Replace the flimsy wire with a stiff piece of metal and screw the tip into it...

Wrap a layer of paper or paper tape on the form first to delete all unevenness in the form.

@jtkilroy

4 жыл бұрын

Its not a form, the coil is staying on that piece of pipe. It is part of a proximity switch for an object inside the pipe.

@bigun447

4 жыл бұрын

@@jtkilroy That was obvious being the tube was cut smaller where the wire went. I suggested the paper just to make the wire lay better and not be run off course by a tool cut. Would not hurt the effectiveness of the proximity coil. You could even use the famous Red Green tool, duct tape. Just kidding about the duct tape, but then??? Keep firing up your video camera, we all miss you.

does your lathe need some TLC? sounds like noisy gears!

@jtkilroy

4 жыл бұрын

Got a reeves drive that has worn bushings, makes a racket. I am going to replace it with a 7.5hp motor with a VFD, got all the parts, just not not the time.

Nice idea - Probably going to need a triangular "spider" to hold that tip. That way the tension on the wire doesn't pull it side to side like its doing right now. Like to see where this goes! Or similar to kzread.info/dash/bejne/pZdputuDZZyafag.html