Post by Marathonman on Aug 31, 2019 12:44:34 GMT -6
In this thread i will teach just how one can create their own custom bobbins at home with little money from recycled plastic bottles in the form of cloth. the below pic is the product in question. it is craft felt cloth found in the craft section of many department stores around the world. it can be cut and shaped to almost any desire. use super glue to glue into place then coat with fiberglass resin with a final finish that is very strong and light weight. it makes excellent bobbins to place on a winder winding just about any type coil you want. my very device i have is built with these very same home built bobbin cores. cloth is about 24 cents a piece at WallMart.
Post by Marathonman on Aug 31, 2019 13:31:37 GMT -6
The supplies needed for the bobbins construction are as follows.
Scissors, ink pen or marker, straight edge, ruler or tape measure, resin, mixing tub, measuring shot class, super glue or some other type of quick drying glue, scraper, Acetone or similar for clean up and a rag.
after you have your core built it is much easier to use your core to make your actual bobbins. if not i would suggest wooden blocks the same size as your cores whether being round, square or rectangle as all jigs are a good thing. with the jig or core in hand you can then begin to measure and cut the clothe needed for your bobbins. if like me have a shit load of bobbins to make it is very wise to cut you some templates out of material that will last a while. it will then make it mush easier to plow through a whole bunch of patterns very quickly.
below is such templates i had cut from aluminum. you know you need these because once you make one device i will be darn if you would stop there. i have 24 total bobbins to make so this is a must for me.
Post by Marathonman on Sept 1, 2019 10:08:26 GMT -6
So then you gave your cores in hand or the templates from above we then need to draw and cur out the cloth needed to construct the bobbins. once traced out cut each one as many as your build calls for. below is the previous build that had round cores which were destroyed by my ex roomates and my new square cores i purchased from Temple Transformer.
as you can see this tutorial will cover two types of bobbin making, one round and the other square.
Post by Marathonman on Sept 1, 2019 10:23:04 GMT -6
The easiest way to get the required length of you cloth needed for your bobbins and your shiny new templates is take a piece of cloth and wrap around the core leaving a little to play with then measure. any excess can be cut off later. trace out then cut the clothe needed for your bobbins. if you are connecting the end caps on the end cut the cloth minus the thickness of the end caps. if you are attaching then to the side of the bobbin body then the cloth is full length. below is start of round and square bobbins that will wrap around the cores or jig if you have it.
Post by Marathonman on Sept 1, 2019 11:36:21 GMT -6
Now that you have everything in place lets begin by keeping the bobbin from sticking to the core. i have actually tried a few things and what i ended up doing is wrapping my cores as tight as i could with thin paper role or plastic. this is to give the bobbin a little gap between it and the core to slide on better. with this in place you can then wrap your cloth around the core and super glue into place holding until dry. once at this point you are ready to start adding resin to the bobbin body.
the round core shown have no paper or plastic barrier were a complete monster to get unstuck so pleas take precautions. after the barrier was in place i used cooking oil on the paper for a non stick effect which worked rather well. make sure the paper is as tight as can be then wrap your cloth around that and super glue into place. cut off excess overlap cloth.
Post by Marathonman on Sept 1, 2019 11:44:06 GMT -6
You can now cover the body of the bobbin in resin following the instructions on the resin mixing. i think this one was 10 drops of hardner to one once of resin but i always buy more and use more drops. use plastic tub for the mixing of resin and a brush. use Acetone for clean up and rag.
Post by Marathonman on Sept 2, 2019 7:27:04 GMT -6
After the bobbin body has a coat of resin its time to make the end caps. they can be coated with resin first then then attached to the body or can be uncoated then attached to body. there is also two ways to to go about this. you can cut the center smaller to attach directly to the end of the body or widen the center hole and attach to the outer wall of the body. either way it works just fine all depending on the length of your core body. below is the end cap cut outs. for the most flat bobbin ends i would suggest two sheet metal pieces tightly wiped down with cooking oil with both sides coated with resin then sandwich them and let dry over night. the pieces will be board flat then just sand down and attach the same as above.
Post by Marathonman on Sept 2, 2019 7:39:32 GMT -6
Attaching the end caps one at a time. you have to let each one dry before attempting to attach the other end. the use of a completely fat surface is a must. you can also take this time to sand the ends to make sure the ends are true. i used a belt sander i purchased from Harbor Freight, it has a 6 inch disc sander with it that has a guide to true up my ends.
when attaching the ends coat the area of attachment with a generous coat. any such bad spots can always be sanded later as will the overlap of the body that was super glued. i have found that a clean flat metal surface works best with a light coat of cooking oil for non stick. a butter knife pops them right up and the excess scrapes right off.
Post by Marathonman on Sept 3, 2019 9:52:13 GMT -6
Now it is time to flip the bobbin to attach the other end cap doing the same thing as before. unfortunately i do not have picture of square bobbing attaching second end. also i added in this step an extra end cap to one side where the wiring goes as i found that only one end cap was to week to be twisting wire through it causing it to crack. so the added end cap on the wiring end of the primaries solved this problem.
Post by Marathonman on Sept 3, 2019 9:59:34 GMT -6
Now that the ends are attached it is time to sand all the imperfections. i found that the Octo sander coming with many attachments ans a belt sander is the best for doing bobbins. after a complete sanding it it time for another coat of resin. this is a good time to cut slots in the end where the wiring will be. these slots make it weaker so that is why i added and extra end cap to the wire end. after the resin is dry cut the slots in the end caps to feed the wire through when winding. a Dremel tool is best for this as a Zaw saw or jig saw will crack and break the ends.
Post by Marathonman on Sept 4, 2019 12:03:02 GMT -6
Adding multiple light coats on your bobbins is the best way to go as i have found. let dry 24 hrs between each coating. the end results can either be painted or left plain as it doesn't change the performance of the bobbins. lightly sand between each coat of resin makes for a smooth surface. your bobbins are now ready to wind on as they are strong as can be at this point.
Post by Marathonman on Sept 4, 2019 12:32:18 GMT -6
With either round, square or rectangle cores it doesn't matter these bobbins can be made to order in your own home and do not have to purchase expensive bobbins or material to construct them. your projects you build is only limited by your imagination and one's ability to step outside the box. half the battle of creating things is the fear of failure it's self within one's mind. so what if you screwed up the first time or two the most important thing is to keep doing it until you get it right. this is the most significant thing about humans is they are self defeating thus cutting them selves off from being creative.
the below pics is me getting out of my comfort zone using a hand winder i bought off of Ebay with a 1/2 inch drill motor attached to wind my coils. word of advice; use a brass or copper nudge to nudge the wire over to keep it tight and not to scratch the magnet wire coating. remember no metal or sharp edges on wire.
Post by Marathonman on Sept 11, 2019 6:52:39 GMT -6
Out of all the bobbins i have made i would have to say that the round bobbins were the easiest to make and wind. they also used the least amount of wire to wind which with the cost of wire now a days was very welcomed. be fore warned square bobbins take a lot more wire but the facts are the only round cores i had were mega expensive being pure iron cores. to have round laminated cores made to order will also dig very deeply into your pocket. it would be a possibility to have the lamination laser cut but then again it will hit the pocket hard. in the long run i found that for top quality lamination it was it was the cheapest to just order plain grain oriented lamination and assemble them myself as opposed to having them assemble them for me. what i ended up saving was a whole lot of money with the end result of having a device capable of hitting near 10 kilowatt output. of course i could of saved even more money and found or purchase burnt out transformers, cut then reassembled them myself then make my bobbins but in the area that i live in scrap anything is very hard to come by so i did what i had to do at the time to get the job done.
with the finished bobbins wound i am very happy the way they turned out. maybe next time i can try my hand at 3D printing the bobbins that i designed in Emachine shop and see how that turns out. the pics below are the 3D bobbin part i might try next time. all i have to do is glue one end cap to the core which was designed to save 3D printer support material. i have found that some glue holds better than the material it's self so i have no problem with that.
just so people know Ultimaker Cura opens Emachine Shop STL export files with no problem then slices for your printer of choice and the fact that Cura is a free download as is Emachine shop.
Post by Marathonman on Sept 16, 2019 18:55:46 GMT -6
whether you are making bobbins with the recycled bottle cloth or using a 3D printer it is not hard to make your own bobbins. half the battle is upstairs between your shoulders that tells you you can not do that. get out of your box (the comfort zone) and try things, you just might surprise yourself. Emachineshop is not that hard to use and you surely do not want to order from them as their prices are through the roof. you can then export as i said to STL file then import to Cura. the whole idea is to make the Figuera device adjustable everywhere as to get the proper balances between the primaries. using bobbins allows you to be able to adjust the coil on the core if need be.
Post by Marathonman on Sept 30, 2019 10:42:15 GMT -6
In the near future i will add a tutorial on this thread on how to make bobbins in Emachineshop which is FREE. once you are finished with your bobbin layout you can export an STL file which can then be imported to Cura also FREE which can then be 3D printed. you can literally make any size shape you want as long as the 3D printer can print it out. depending on the material and your settings you can use supports to print the entire bobbin or save material and print the end cap and the main body then print the last end cap separately. this saves a lot of support material especially if you have a shit load of bobbins to print out like i do at 24 total bobbins. i found some clue on line that when applied to the material that the glue held better then the actual material did, the material broke before the adhesive did. that kind of strength is fantastic for bobbins.
you can even send it to someone to print it out for you if you do not own a 3D printer but be forewarned that will cost you. just goggle for local 3D printing services.
Edit; i almost forgot about Slicr3 thanks to Peter reminding me. there are others that are free also just google.
the adhesive can be found in a few places but i would suggest using this information from hack-a-day which is a unbiased real world test not a paid advertisement. i give them 50 thumbs up for not kissing Corporate's big greedy ass on this one.