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Primary Coil Constuction

A project log for Tesla Coil

Medium Sized 22" Tesla Coil, currently standard, but working on conversion too solid state so it can be musical.

leo-mahdessianLeo Mahdessian 01/14/2016 at 15:160 Comments

The primary coil consists of 50' of 1/4in copper pipe that is spiraled outward from the secondary coil mounting point. There is 14 turns of the piping. To hold the copper pipe in place, four acrylic mounts were laser cut and glued to the base. The acrylic is 1/4in thickness. Here is a photo of the laser cutter: (The laser cutter was located at Nova-Labs in northern Virginia, check out their website here: Nova-Labs.org)

Here is a photo of one of the mounts half done:

After glueing the mounts down, we realized that the slots were deep enough for the copper pipe to stay in the desired shape. Painstakingly, we drilled each slot deeper with a drill press, and used a bandsaw to remove any excess acrylic. Afterwards, we glued the mounts back down to the base. Then we took the copper tubing and spiraled it into each slot. The one advantage to drilling the slots deeper was the pipe snapped into the mounts. After all the pipe was spiraled, we used a 1/4" piece of wood to make sure the spacing between each turn was 1/4". Then we used a piece of scrap wood to make sure the height of each turn was equal. After, we used hot glue to secure the copper to the mounts. (I would recommend to use 8 mounts instead of 4 like we did. It makes the spacing between the turns more equal.)

Here is a photo of the completed primary:

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