[Drew Pilcher] wanted sturdy, custom-wound coils with no core, and completely flat sides. Coils might be wound by hand, after all, however reliably creating excellent coils with skinny wire and plenty of layers requires some extra assist. Fortunately, [Drew] shares his method for doing exactly that. Maybe coming as no shock, the important thing to repeatable, high-quality coils is sweet preparation and instruments.
An important half is the flexibility to rotate a spool for winding with out having to take one’s arms off the workpiece. To perform this, an affordable, no-name energy drill and foot pedal (comprised of the harvested set off unit of the drill) varieties the idea of [Drew]’s DIY winder. To make coils with precision, one should additionally rely the variety of turns. Fortunately, there’s a easy answer for this; [Drew] used an affordable digital flip counter from Amazon. This economical gadget makes use of a magnet and sensor, so [Drew] merely caught the magnet on the aspect of the drill’s chuck.
The spool is what the wire will get wound round to type the coil, and it’ll should be faraway from the coil afterwards. To perform this, [Drew] makes use of a brass shaft, metallic washers, and a few plastic spacers. A light-weight coating of grease on the spool surfaces helps guarantee issues come aside correctly ultimately.
To really make the coil, [Drew] recommends some technique of magnification, and a provide of CA glue. Wind the wire as cleanly and intently as attainable, and apply CA glue throughout the course of to safe issues. It takes some follow, however actually clear windings are attainable if finished accurately.
For thick coils with lots of layers, the CA glue will maintain issues collectively effectively sufficient, however for smaller coils [Drew] likes to offer them a ultimate coating of two-part epoxy. After issues are utterly set, the spool is disassembled and the interior core is pushed out as gently as attainable.
The consequence? A tightly-wound, sturdy coil with completely flat sides. It’s precisely the factor [Drew] wants for his upcoming coil gun venture. How’s that work, you marvel? You can see the basics covered right here.