This is a guide on how to build a medium sized Tesla coil. I built this one from parts I had laying around, all I had to buy was magnet wire, in all I spent less than $30! For those building their first coil, I would not suggest using this a standalone source of instructions. This is my first coil, and I used a multitude of sources to make it. Also, I did the boring math part behind it. At first I tried to skip some of the math, and just "wig it" but that didn't work. For the math part I would suggest deepfriedneon.com, but I found a much simpler site : http://www.classictesla.com/java/calculat.html#WireFreq . Once you know what materials and dimensions you will use, go to this site to get the whole resonance thing synced up as closely as possible. Read this entire guide, and maybe the comments section, before doing anything. Also read some other guides and maybe the Wikipedia article on Tesla Coils before deciding whether or not to embark on a shockingly frustrating, but rewarding journey. I built this for a high school science project, and although I finished at the last minute, it didn't take more than maybe 20-30 hours of work. I entered a few contests with this so you should vote for me if you enjoy this instructable.
I also must say that by using any information in this guide you assume all risks involved with the components, operation, and construction of Tesla Coils or any part of the circuitry described. I do not take any responsibility for injury or damage resulting from the use of this information. Tesla Coils CAN KILL YOU! Whether it be the streamers, 15kV NST output, or the simple (and most dangerous) 120V wall outlet input. All the currents involved with this project are dangerous! I would recommend working with someone experienced with high voltage if you are not. Also, this device is a major FIRE hazard. Use it only outdoors. To sum it all up, this project is risky, be careful.
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Signing UpStep 1: My Understanding of the Inner Workings of a Spark Gap Tesla Coil
From what makes sense to me, the Tesla coil is a magnetic resonator, otherwise just a really powerful transformer. Wall outlet current is converted to 15000 V by the NST, which then charges capacitors, which (once fully charged) allow electricity to temporarily "jump" the spark gap, which allows current to temporarily flow through the primary coil, generating a magnetic field, which the secondary picks up, and converts it back to a current (of higher voltage), which then flows into the ground and into the air (What a sentence!). This process happens 120 times per second or something like that. The Tesla Coil not only steps up voltage but also frequency, which makes the pretty streamers of death that obviously fascinate you (that's why you are here). Due to this high frequency, your nerves would not feel pain from the streamers conducting into your body, but they still cause damage! Basically, your insides would cook and you wouldn't feel a thing, but that is not going to happen because you are not to touch the streamers! Don't do it! Oh yeah, the diagram is from Wikipedia, thanks to another instructable to pointing out to me which one to use. Use the bottom diagram. The top one didn't even work when I tried it, and the bottom one makes more sense.
For the High Voltage transformer, I used a 15kV NST.
For the spark gap, I used two bolts in opposite sides of PVC pipe at a set distance.
For the HV capacitor, I used salt water "Leyden jar" capacitors made of Snapple bottles.
For the Primary, I used .25" diameter copper tube.
For the secondary, I used 24AWG magnet wire wrapped around 1.5" PVC.
For the Torus, I used Aluminum Dryer Duct that I cut open and wrapped around two aluminum pie pans.
For the High Voltage transformer, I used a 15kV NST.
For the spark gap, I used two bolts in opposite sides of PVC pipe at a set distance.
For the HV capacitor, I used salt water "Leyden jar" capacitors made of Snapple bottles.
For the Primary, I used .25" diameter copper tube.
For the secondary, I used 24AWG magnet wire wrapped around 1.5" PVC.
For the Torus, I used Aluminum Dryer Duct that I cut open and wrapped around two aluminum pie pans.
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I just have two tips for you:
1) People aren't as smart as one might assume. I've seen this happen on my own Tesla Coil instruct able.
2) Try a shorter, fatter secondary. I have seen this common misconception happier to even some of the more experienced coilers. You will get a much better output for all the work you are doing. ( Congrats on getting what you did! )
A good ratio for secondaries is about 3.5-6 times the diameter is an appropriate height. So say you had 3 inch O.D. PVC, an optimal length would be around 12 inches. Stick by this and you will see a great increase in performance. A side note:
As tesla coils use resonant rise, turn count DOES NOT MATTER. Thus, height has no advantage.
An exception: on the smaller end of diameters, you want to a ratio of 5 MAX.
I've made about 900 turns for my secondary coil instead of 1000. Will it work?
http://www.harborfreight.com/2-piece-welding-goggles-set-35711.html
If you have to ship these its proably still worth it but i live by a HF and with 20% off i can get them for about $3.50
http://www.mediafire.com/view/?6y7gi6u3qi8miai
copper tube with 10 turns secondary made with 2inch PVC pipe.Winding
height 10.2inch(0.315mm enameled copper wire used) also made Capacitor
bank with 2kv 0.15uF polyester film capacitor.But the problem is my
Capacitor burnt several times but the coil works with LEYDEN JAR
capacitor.Why the capacitor burning??????
Please Help Me!!!!!!!!!!!!!!!
be careful be very very careful!
It is a very common misconception that tesla coils need to run at high frequencies to be considered tesla coils, when in fact they actually need to resonate.
You also mentioned the skin effect. As MistaStokes said, the skin effect apply very well to human flesh. Instead its the incapabilities of your nervous system
It would also use like 10 tons of copper wire!!!
Probably safe to say that its impossible.
I really want to build another coil too. My first one was a little 12" tall coil that throws 6 inch arcs at best and my second was a VTTC that throws 7-8" streamers. I want to see 2 foot arcs!
I'm having the same problem. I can't find any transformers on craigslist and they are way too much on ebay, well the high power ones are. I might start to call around a at neon supply and repair shops.
Pole pigs are very heavy, upwards of 200-300lbs, very hard to come by and very expensive. My guess it that it would be easier to buy one than to make one because it will require a lot of iron (specially shaped) and even more copper wire. I know people have had very good success powering large coils, 4 feet tall or bigger, with nst and microwave oven transformers (MOT). It takes a fair amount of math and understanding to make one that big with good results, but i think its worth it.
I recommend using a 15kv NST at 30 or 60 mA or 2 MOTs in series with a voltage doubler to get 8kv at a few hundred mA.
check out here: http://en.wikipedia.org/wiki/Skin_effect and here: http://www.bibliotecapleyades.net/tesla/esp_tesla_17.htm
Basically DO NOT TOUCH this or any other Tesla coils. The skin effect is NOT enough to prevent permanent nervous and muscular damage, or even worse, cardiac arrest.
If you want to touch the streamers, get yourself a Faraday suit, like ArcAttack and other professionals do.
It only takes once to kill or maim...