Quick and Dirty Hand Held "Tesla Coil"

 by hardwarehacker
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This is a very dangerous hand held high voltage generator. I built it from an auto ignition coil, power relay and a broken power drill. I call it a Tesla coil because that is what an ignition coil really is. It's a very convenient short cut to a high voltage spark generator.

You could build it with any power supply from 6 to 12 volts if you do not have a broken drill laying around.


This is a total hardware hack. I know it looks like crap. We were having a party and I wanted a prop that would scare people. I threw it together in about 2 hours. I've spent three times longer documenting the build than I did actually building it.

I have a really well stocked junk collection, so everything that I used to build this was actually laying around the shop before I started building it. The design is very flexible and will work with whatever junk you have.
 
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Step 1: The power source

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I had a broken power drill. The trigger, PWM power control, and the battery were still fine. I removed the reversing switch, as the relay and coil only need one "direction".

I relocated the PWM power transistor to the side of the drill handle, because there was no room for it inside after the top of the handle broke off.

I attached two heavy (16 GA) wires to the power output of the drill speed control.
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ben123324 says: Jun 30, 2011. 7:37 PM
uuuuuuhhh... why does everyone call sparks a tesla coil? this is NOT an air core resonant transformer of any kind. it is cool, but just call it a high voltage gun or something
hardwarehacker (author) in reply to ben123324Jun 30, 2011. 8:10 PM
Why does everyone think that Tesla only made air core transformers? The great one had a patent on the ignition coil, if anyone bothers to look it up...
manbearpig001 in reply to hardwarehackerAug 20, 2012. 2:57 PM
An ignition coil is an air resonant transformer. Same setup as a TC without the tank circuit involved. He was very involved in distribution of power, and his primary focus was air resonance. He did improve some iron core transformer designs in his early career though.

-Andrew
andrewbourhis.blogspot.com
ben123324 in reply to manbearpig001Aug 25, 2012. 5:26 PM
no, an ignition coil is not an air core. its a gapped iron core. tesla patented just about everything edison didn't steal from him, but that doesn't mean that everything he built that contains a coupled inductance is labeled "tesla coil" .

and aside from the rant, heres a REAL tesla coil gun if i've seen one. all credit to steve ward himself...

http://4hv.org/e107_plugins/forum/forum_viewtopic.php?140268
TeslaBoy says: Apr 15, 2012. 2:57 PM
I tried the relay but even by changing the voltage to change the oscillation pattern the performance from my coil was still bad i was able to pull about a cm. I am hoping that a 555 timer with a hv diode and 2n3055 transistor will have a better effect
hardwarehacker (author) in reply to TeslaBoyApr 15, 2012. 3:22 PM
With this tuned right I have pulled over two inches from a standard car coil. You need to have a mass of metal on the secondary to tune it, that is the function of the rod that I put into the HV output. Different coils will need some tuning of the "top" mass and the primary capacitor. When it's working right there will be hundreds of volts from the primary flyback, so the 2n3055 will not survive that. if you clamp the flyback with a diode (like you would do with a relay) you will kill the ringing and not get the highest voltage.

There are lots of people saying "not a tesla coil" but the way I have this hooked up you have the issues as a big coil. It's not working as a simple transformer, but doing something like the resonant transfer of a air coil. This very high voltage from the ignition coil is coming from the disruptive arc on the primary and the ringing of the primary interacting with the secondary and the "top" mass. I have not seen this kind of voltage buildup with a transistor switched drive.
TeslaBoy in reply to hardwarehackerApr 16, 2012. 6:51 AM
Thanks for the further information and to let you know your prediction happened instantly yet I anm just going to change the transistor to a MOSFET
hardwarehacker (author) in reply to TeslaBoyApr 16, 2012. 9:06 AM
For the maximum secondary voltage, the primary has to ring. This makes it very hard to drive with a solid state device, as the primary ringing will build up high voltages on the primary side. Be careful, as I blew out a nice power supply with this primary flyback while testing this the first time.
electronicz says: Apr 3, 2012. 4:02 PM
Could the relay be replaced by a P-channel JFET?

Like this:
P-CHANNEL JFET.JPG
hardwarehacker (author) in reply to electroniczApr 3, 2012. 8:02 PM
you could drive the coil with a transistor or MOSFET, but It would be easy to blow out a solid state switch. With a relay you get a bigger spark because of the "disruptive" arc in the primary.
electronicz in reply to hardwarehackerApr 4, 2012. 7:55 AM
Thanks, 5 stars
nerd7473 says: Oct 26, 2011. 12:57 PM
this is so cool i dont think may parents would let me build this
ilpug says: Oct 13, 2011. 10:28 AM
This can kill you.
pastaking says: Sep 6, 2011. 1:16 PM
One Word: PORTAL GUN! (Ok that's two, but "Two Words: PORTAL GUN!" doesn't sound as good!)
CeasarVictus says: May 2, 2010. 8:21 PM
Could you also use the potentiometer on the Dewalt trigger control, to vary the output of a 555 timer? And get oscillations that way? I'm not sure myself, just a thought.
hardwarehacker (author) in reply to CeasarVictusMay 3, 2010. 5:53 AM
You could,but I like the raw, ragged chatter of the mechanical relay oscillator. (it's much more menacing than a tone)  Also using the relay this way there is nothing that can get blown out by the voltage spikes.
Gaark in reply to hardwarehackerSep 6, 2011. 4:36 AM
dude I love that chattering noise too, I used to hook up relays just to let them buzz old batteries dead lol

This would make a great 'steampunk' item with a little dressing up! Go for it!
shams says: Jun 1, 2011. 9:28 AM
Ahm...Its not a Tesla coil
imshanedulong in reply to shamsAug 8, 2011. 9:30 AM
That's why the name is in quotations...
hero 54123 says: Jul 8, 2011. 11:14 AM
would it be possible if i, make the coil shoot lightning farther,make the body longer and add rubber to it and make the wunder waffe DG2, from call of duty nazi zombies?
justjimAZ says: May 13, 2011. 6:32 AM
Would make an interesting portal gun.
http://hacknmod.com/hack/make-your-own-handheld-portal-gun/
aweis says: May 12, 2011. 5:35 PM
where would i get any of those things mentioned here? I do not understand how this works, therefore i cannot make it, the oscillator does it basically spin alternating which of the three wires gets the current? and what about the contacts that are normally closed it seems that you only half finished that sentence.
aweis in reply to aweisMay 12, 2011. 5:47 PM
ah those three wires are ground wires
aweis in reply to aweisMay 12, 2011. 5:37 PM
and by three wires i mean the ones that are at the end of the tesla coil gun that creat the spark gap to the secondary coil or what i presume is the secondary coil.
tzq33tdq says: Oct 7, 2010. 1:02 AM
quick qestion will it hurt if i touch the sparks???
aweis in reply to tzq33tdqApr 15, 2011. 6:31 PM
depends after a few seconds probably not, but initially it will most likely, maybe kill of some nerves.
Delo97 says: Apr 10, 2011. 2:24 PM
This reminds me of the rifle from "Bender's Big Score"...but I don't think it's so powerful...
Antitheus says: Mar 24, 2011. 5:21 PM
you should build a little flame at the end from an old lighter.
the flame will make the air A LOT more cunductive!
with my 9 KV power supply i get sparcs about 0.5cm when there is a flame nearby I can reach 2-3cm
rkumble says: Feb 25, 2011. 1:27 AM
can some one send me the schematics for this i cant figure out wat to do in the insturctable
Username_already_taken says: Dec 17, 2010. 3:52 PM
If you're still reading this HH, is the filter needed if one is using a hard on/off switch? I have the oscillating relay down, but when I connect the + from the batt straight to the terminal on the coil it simply shorts and the relay stops. Thoughts? Is my coil bad? I measured continuity from + to the ferrite core, is that normal?
wjbeaty in reply to Username_already_takenDec 20, 2010. 11:00 PM
Primary must be floating! If your type of automotive coil has one side of primary coil internally connected to the case, then it won't work unless you alter the circuit.

In the schematic, flip the whole relay-buzzer section horizontally, mirror image, so the relay coil L2 connects to ground, and the SPDT switch pole C1 connects to +DC. (Swap the polarity on the 220uF, of course.) Now the relay should still buzz, but the C2 switch contact is now getting connected to +DC instead of to ground. Next, use the resistor to connect switch contact C2 to the primary coil terminal screw (to the one that's not connected to the case.) That sends pulses of +DC to the primary coil, while the other primary screw gets grounded.
forwardbias says: Dec 15, 2010. 8:44 PM
Ignition Coils by themselves are not dangerous, they produce up to 50KV but at low current. 9mA max I think I read. At the most if you touch the output from one, you will yell OUCH!!! and you will have a burnt finger.

What makes this dangerous is that normally, to be "safe" its recomended that you use an AC to DC power supply 12-24 volts, that isolates the driver circuit from the dangerous mains current. Driver circuits are out there that use such supplies. The mains current from a normal Outlet can produce up to 10 or 15 amps short circuit before the fuse or breaker trips. Thats more than 1,000 times the current of the coil. Meaning you get 1,000 times more current going through your body if you accidently touch something wrong on the input end of the coil, than if you had used a proper isolation power supply and driver circuit.

Instead of saying OUCH!!! You go say hello to your great, great, great, great grand parents at the pearly gates...

A simple computer PSU you might have laying around is good, run the driver circuit, off the 12 volt rail. You will need to know an understanding of electronics, reading schematics and some solid state stuff. Which an ignition coil needs a pulsed DC signal. Though Using a rheostat directly connected to mains might work with junk laying around, its dangerous, and coils like that are not designed to be run off 60HZ AC signals, even if you lower the voltage input. Might be fun for a short life zapper though.

A safer, long lasting ignition coil set up, I would advise using a power supply, isolated from mains, and no more than 24 volts. Much like with flybacks, if you feed too much input, you will burn up the windings inside. And you dont want to just burn up an ignition coil, brand new, they are not cheap. So unless you have a cheap supply of ignition coils, best to use a driver circuit. A set up like I mentioned can be used to make home made plasma globes, small tesla coils, make your own x-rays or electron beams, and ion experiments.

With electricity, its always best to be safe. Dont take shortcuts. If you dont respect electricity, its like playing Russian Roulette. You might get away with it once, twice, maybe 3 times, keep pulling the trigger though, eventually, you will run out of luck, and your numbers will be up.


_-MacGyver-_ says: Dec 15, 2010. 3:55 PM
Holy COW! Thats a real live flux Capacitor! At about 26-28 seconds in your youtibe video it looks like it!
flux.jpg
mr.handyman says: Dec 10, 2010. 4:42 PM
Great idea.....
#Gruber#
tzq33tdq says: Dec 5, 2010. 3:42 PM
will i get hurt if i touch the sparks
Jimmy Proton says: Aug 24, 2010. 6:44 PM
this is cool, it gives me ideas to build somthing like it, probable simpler
briackman says: Jul 10, 2009. 9:02 AM
awww, do you have to use a cap
hardwarehacker (author) in reply to briackmanJul 10, 2009. 9:48 AM
The cap and inductors are there to prevent the high voltage spikes from blowing out the speed controller in the drill handle. The Cap also provides a large current spike into the coil to enhance the output voltage.
briackman in reply to hardwarehackerJul 11, 2009. 5:57 PM
so can i use a smaller cap than that, or is it not safe?
Jimmy Proton in reply to briackmanAug 24, 2010. 6:38 PM
depends on the ratings not size
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