Junkbox Build Keeps Tesla Coils Perfectly Varnished
Admittedly, few people have a regular need to varnish coils. This is primarily something that Tesla coil builders and other high voltage experimenters are concerned about. But since this group probably constitutes a sizable fraction of Hackaday’s audience, and because there are probably more applications for this homebrew reel varnishing setup, we thought it would be a good idea to share it .
For [Mads Barnkob], coil maintenance is not something to be taken lightly. If you check out his Kaizer power electronics on YouTube, you’ll see he has a whole collection of big, powerful Tesla coils, some of which are used for demos and shows, and some that seem to be reserved primarily for blowing stuff up. To prevent one of its coils from joining this last group, it is essential to maintain the layer of insulating varnish on the secondary windings of the coil in perfect condition.
The setup seen in the video below helps with this tedious task. Constructed entirely from scrap and junk parts, the low-speed, low-precision lathe can be configured to accommodate spools of all sizes. In use, the lathe spins the spool very slowly, allowing [Mads] to apply an even coat of varnish to the surface of the coil and to prevent it from sagging while it dries.
[Mads]The setup is probably not ideal for winding the coil as is, but for servicing the coil it is exactly what is needed. If your needs are more like a coil winder, we have a fully automated winder that might be right for you.