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Madness
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Posted: 31 May 2017 at 2:26am | IP Logged Quote Madness

Hi Andrew,

Yes, I straightened the wire, if not the kinks are going to make it into a bulky rats nest.

As for stripping the enamel off the wire, I find a sharp cutter is very good for scrapping it off, much quicker than sand paper IMO. Another trick I found is a pair of wire strippers I have that have 2 V-shaped jaws a bit like a parrot's beak with an adjustable stop, set it to the right depth and draw it off the end with abut 4 or 5 strokes at different positions.

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Warpspeed
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Posted: 31 May 2017 at 3:39am | IP Logged Quote Warpspeed

All excellent advice.
My favorite method of copper wire straightening is to anchor one end in the bench vise, run the whole length out across the back lawn, and just stretch it tight.
You will feel it stretch slightly and not spring back.
All the bends and wobbles will then be gone.

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Madness
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Posted: 31 May 2017 at 5:35am | IP Logged Quote Madness

To get the sharp kinks out of the wire from the Aero-Sharp toroids I have found they have to go through 3 bearings to get them straight. Or perhaps Warp you live in a better paddock than me, although I doubt it.

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Warpspeed
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Posted: 31 May 2017 at 5:54am | IP Logged Quote Warpspeed

You should not have any sharp kinks to begin with !

If you do then a very gentle un-kinking is called for.
If a kink is pulled tight, you are in trouble.

My advice only works with wire that has been very gently removed and very gently treated.
The problem with copper is that it very readily work hardens. Every time it is bent and un-bent it gets stiffer and becomes much more difficult to work with.


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Madness
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Posted: 31 May 2017 at 8:37am | IP Logged Quote Madness

I am talking about the sharp 90 degree bends already in the wire from the corners of the toroid, only way I have found to get them out is to use Oztules method with 3 ball bearings.

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mackoffgrid
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Posted: 16 June 2017 at 6:17am | IP Logged Quote mackoffgrid

Thanks Madness, Oz, Warp, Et al.

I successfully made my primary cable using 19 strands and wrapped it with tape as Oz did. Transformer seems good but wont be able to do much testing - I'm pretty slow and life / other projects slow me even more.

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