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Author Topic: DIY Flapjack Coil Jig  (Read 43238 times)

Offline z.monkey

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DIY Flapjack Coil Jig
« on: January 23, 2009, 07:10:32 PM »
Howdy,

Been having a hard time finding information about winding planar coils.  Now-a-days they are all printed on a circuit board in those very expensive DC to DC converters.  There are not many garage engineers out there that are dealing with these type of coils I guess...

So I decided to use a CD-ROM as the "substrate" for the coil.  The wire will be glued to the CD in the final form.  I needed a way to hold everything together until I could apply glue to it.  So the base is a piece of 3/8" plywood.  There is a center shaft which is a 1/4" machine screw.  I used some strategically place fender washers to be the inside wall for the windings, and also provides the correct spacing between the base and the holder arms.  The holder arms piece was originally plywood, but I found that it didn't have the structural rigidity that was required.  So I fabricated another piece out of 1/2" thick fiberglass board.  I would really like to make this out of aluminum, but that is mo $$$.  So far I build the entire thing out of scrap materials laying around the shop, so its free, right?

I'll post some other pictures later, after I get the coil glued together...

Offline broli

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Re: DIY Flapjack Coil Jig
« Reply #1 on: January 23, 2009, 07:16:02 PM »
Wow that's quite smart. Thanks for sharing.

Offline z.monkey

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Re: DIY Flapjack Coil Jig
« Reply #2 on: January 23, 2009, 09:06:32 PM »
Here is the finished Flapjack Coil...

Offline Yucca

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Re: DIY Flapjack Coil Jig
« Reply #3 on: January 23, 2009, 09:55:24 PM »
Very tidy result Z.Monkey! See you´ve got the in circuit debugger on the bench ;)

Offline z.monkey

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Re: DIY Flapjack Coil Jig
« Reply #4 on: January 23, 2009, 11:15:15 PM »
I don't want any buggers in my circuits...

I have the primary built now too...

I'll take a picture when I get home...

Offline z.monkey

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Re: DIY Flapjack Coil Jig
« Reply #5 on: January 24, 2009, 02:40:40 AM »
Wow that's quite smart. Thanks for sharing.
Hey Broli,
I would like to say that I just threw the thing together and it all worked...

But, you know, engineering stuff never works like that.  I probably spent about two full days fabricating.  I probably spent like three weeks thinking about how to do this.  I remember seeing pictures of Tesla's"pancake" coils, but how did he manufacture them?  That is a big ass problem!  It takes a precision jig to make something like this.  Then you have to take the jig apart so that you can glue the substrate to it...

Maybe it will become easier with time...

Offline z.monkey

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Re: DIY Flapjack Coil Jig
« Reply #6 on: February 10, 2009, 12:13:26 PM »
I decided to use an Iron tube core...

Offline z.monkey

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Re: DIY Flapjack Coil Jig
« Reply #7 on: February 10, 2009, 12:14:29 PM »
This way I can mount it with out putting stress on the flapjack coil...

Offline z.monkey

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Re: DIY Flapjack Coil Jig
« Reply #8 on: February 10, 2009, 12:15:28 PM »
I'll need to build up a pedestal to support the core...

Offline z.monkey

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Re: DIY Flapjack Coil Jig
« Reply #9 on: February 10, 2009, 12:16:02 PM »
Make a pretty outline...

Offline z.monkey

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Re: DIY Flapjack Coil Jig
« Reply #10 on: February 10, 2009, 12:16:35 PM »
I love playing with the jig saw...

Offline z.monkey

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Re: DIY Flapjack Coil Jig
« Reply #11 on: February 10, 2009, 12:17:17 PM »
Lets do a dry fit...

Offline z.monkey

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Re: DIY Flapjack Coil Jig
« Reply #12 on: February 10, 2009, 12:18:07 PM »
Glue the pedestal sections together...

Offline z.monkey

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Re: DIY Flapjack Coil Jig
« Reply #13 on: February 10, 2009, 12:19:24 PM »
Glue the Core to the Pedestal...

Offline z.monkey

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Re: DIY Flapjack Coil Jig
« Reply #14 on: February 10, 2009, 12:20:31 PM »
Ready to wind the primary coil...