Construction of the Coil

The Primary Coil

The wooden form for the primary coil

The copper sheet and the inner tap.

 The other side of the inner tap.

 The finished primary

The Secondary Coil

 The winding jig that was used to make the secondary. I used a 24Vdc geared motor to turn it. It spun at a whopping 8 RPM. If I wound it continuously, it would have taken a little over 4 hours to wrap the 2000 turns.

The form used for the secondary is a 12" diameter cardboard tube used for concrete forms. I had to remove the yellow paper because the ink used was conductive. Unfortunately, it left a 1/16" groove which had to be covered with tape.

I used some cable ties to make a nice starting point for the coil.  I also used a hot glue gun to hold the wire in place incase it started to unwrap while I was winding it.

 A close up shot of the windings. The groove that I taped over can be seen

The Toroids

 To build the toroids, I used some black drain pipe and a wooden circle. The 36" toroid was much easier to form. It was pretty difficult to get the drain pipe to bend into a 24" diameter circle.

I first used string to hold it in place, then I ran some screws through the pipe and into the wooden form.

 Once I got the pipe attached, I covered it with some masking tape to smooth it out a bit.

Then I glued on some aluminum foil.