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Here's my latest coil shell design, an 11 inch concentric. When I saw it molded in black ABS I decided to name it Darth Coil. I'll be swinging this on my Explorer very soon!
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I just received a white version of this coil from Charles (Upstate NY). My first impression was how well it is made; it fits together tight, pieces align very well and is supplied with a cable strain relief, nylon wing nut and nylon bolt.
Here is a coil winding tip for this coil (or any coil). This particular coil has an inside channel width of 1/2 inch. When planning to wind a coil to fit a coil housing, make sure you plan for the bulk of the wire bundle to fit based on the wire size used. Thicker bundles (AWG 22 stranded, 21 turns about 300 uH) of heavy wire (with insulation) will result in a coil wound with a 10.10" to 10.20 inside diameter. You will need to make up a small bundle of your wire with the appropriate number of turns and measure the diameter of the bundle to see which inside diameter will fit better. Don't forget to include the thickness of the spacer and shield. If you are using AWG 30 Kynar wirewrap (20 turns) for about a 300 uH coil, make the inside diameter 10.4" to 10.5, again measure the bundle. Both of these mesurements (thick wire and thin wire) allow enough room for adding a coil spacer in the form of a spiral wrap, and a coil shield and fit the coil shell very well.
I use 16 tall screw hooks places around the perimeter of a 10.5" diameter circle as a coil form. I can bend the hooks to accomodate a 10.1" to a 10.5" diameter coil variation. Measure the spacing of 8 sets of opposite hooks to set an accurate inside coil diameter. These tall hooks provide enough room to secure the coil with waxed line or dental floss while it is still on the coil form.
bbsailor -
I'm shuffling things around a new ISP so the picture link was broken for a while, I have fixed this.Comment
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Looks Good Charles!!!!
Nice design. Looks like it should be very well balanced!
HH
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