I have an amp that had a shorted output filter inductor..
I have the new core and the proper size wire and proper length..
My question Is there a trick to winding these ?
Im wondering how do i keep the wire tight on the core when winding ?
i need 58 turns total and if i leave the wire lose then i have alot of left over and not the correct number of turns ..
So im wondering if anyone has some ideas or tricks that help keep the wire tight or the core in place to pull on the wire with my hand to keep it tight while winding it ?
I have the new core and the proper size wire and proper length..
My question Is there a trick to winding these ?
Im wondering how do i keep the wire tight on the core when winding ?
i need 58 turns total and if i leave the wire lose then i have alot of left over and not the correct number of turns ..
So im wondering if anyone has some ideas or tricks that help keep the wire tight or the core in place to pull on the wire with my hand to keep it tight while winding it ?
Assuming it's a toroid, and the first layer uses up more than half the wire, I usually start winding from the middle of the wire. Saves you from having to repeatedly draw the entire wire length through the core for the first several turns. There's no way to completely alleviate the frustration of hand winding toroids. Go slow and be careful to head off any loops as you draw a turn tight, they're a lot easier to prevent than fix once the wire is kinked. Straighten up each turn as you go, leaving even space between turns on the OD, while trying to keep them tight on the ID. Anything heavier than 20 gauge wire (especially if it's old and hard) can make a hobbyists fingers sore before the job is done, with all the tension required, so take long breaks if you have to. For large enough cores I often use a pen or pot adjuster tool to straighten the ID area after every turn.
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To reduce fatigue in your hands, wear a pair of grippy gloves (like the ones in the photo).
In the photo, you can see a rigidly fixed dowel rod (clamping in a vice would work). Looping the wire over the rod will prevent it from twisting as you pull it through the core.
If you want the coils to lay as flat as possible on the core (around the corners), there are a couple of things you can do. When you have the wire on the outside of the core, you can pull it hard against the corner, pushing it down with your thumb or against a firm surface. Be sure to square the top-outside corner before feeding the end of the wire into the center of the core. For the inside corner, you can work the wire back and forth while pulling on it after the end is through the core.
In the photo, you can see a rigidly fixed dowel rod (clamping in a vice would work). Looping the wire over the rod will prevent it from twisting as you pull it through the core.
If you want the coils to lay as flat as possible on the core (around the corners), there are a couple of things you can do. When you have the wire on the outside of the core, you can pull it hard against the corner, pushing it down with your thumb or against a firm surface. Be sure to square the top-outside corner before feeding the end of the wire into the center of the core. For the inside corner, you can work the wire back and forth while pulling on it after the end is through the core.
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