Wind Your Own Coils Quickly

Ever needed to wind a coil quickly?  
Coils can be used to make actuators, electromagnets, and even to communicate energy! 

I use small copper coils in my micro RC airplanes and I wind my own coils quickly with this tip. (See some of the planes I built on my blog  http://maxoffsky.com/tech-blog/rc-micro-spitfire-airplane-build-log/)

You will need the following :
+ A drill 
+ A thin file (will be the width of your coil)
+ Superglue
+ Cylindrical Wax candle about 8-10mm in diameter (should be bigger than diameter of desired coil)
+ Thin copper wire (you can salvage some from old relays or 1$ mechanical clock found in 99 cents store or Dollar tree).

The making of a coil involves a few steps:
1) making a former out of the wax candle (a template that will hold the wire)
2) wind the coil using the drill and superglue
3) dissolve the wax in hot water
4) use your new coil!

TIP: put the candles in the freezer before you do this, so that they don't melt too quickly while you are working with them.

Let's start with step one :
Take the cylindrical wax candle and put it in the drill like on the second picture, secure the wax candle in the drill.
Now, you need a file and while the drill is spinning you will file away the wax to make a desired shape former. I found out that it works better if you heat the file up a bit and use it immediately while it is still warm. I make a template like on the last picture, so in the profile it looks like letter H where your wire will go.
Do not take the candle out of the drill.

Now that the filing is done, for step two hold the wire bobbin somewhere so that it spins freely, you are about to unwind the old relay wire or the clock wire. You need to secure the other end of the wire on either end of the candle, for example with scotch tape or just on the tip of the candle. I usually make a knot inside the filed-out former and secure the end of the wire to the candle making sure it will not be too short for my application. Now you can do a few rounds of the wire with the drill (put it on the lowest speed) and when you have 10-20 rounds, put a drop of CA glue (AKA superglue), then continue to wind the coil using the low speed setting on the drill. Make however many rounds you need making sure that the glue is still distributing inside of the former and that the coil has enough glue.

Now that the coil is wound, you need to let the glue dry for a few minutes. When the glue is dried, cut out the other end of the wire apart from the wire source (the bobbin of wire), get the candle out of the drill, cut the former that has your coil and put it in hot water to melt away the wax. When the wax is melted, you will have a nice looking coil, ready to go into your projects! 

Enjoy and let me know if you have any questions. If there's enough interest I will put up a video and a better way to make coils!

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    24 Discussions

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    msurguy

    6 years ago on Introduction

    Please vote for this Instructable on the "Electronics tip contest" : https://www.instructables.com/contest/etipstricks/?show=ENTRIES
    I really appreciate your votes!
    Thank you!

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    msurguyDrakekay

    Reply 6 years ago on Introduction

    I haven't tried this with crayons, perhaps you can try and let us know ? =)

    Made it look so easy!! (Rest of them are difficult for a beginner like me, in RC actuators) Cool... a video would be fantastic!!

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    msurguynadav

    Reply 6 years ago on Introduction

    I've added more pictures ! Check them out and let me know if anything in the process is not clear.

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    msurguynadav

    Reply 6 years ago on Introduction

    Yes, I will provide some more pictures in the next couple of days, I wanted to see if there is demand for this kind of thing, thank you for letting me know that you'd like to see more!

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    Tomdf

    6 years ago on Introduction

    Very nice, I'm glad I saw this before I tried doing it the way I had planned. That candle tip probably just saved me an hour of frustration :D
    Thumbs Up!

    1 reply
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    msurguyTomdf

    Reply 6 years ago on Introduction

    Thanks Tom! this could be made into all kinds of things, I'm planning to shoot a little video and add it here so people can see what's the use of these coils...

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    bobby sissommsurguy

    Reply 6 years ago on Introduction

    very nice, now that I know the approx. demensions i can at last make my hamster wheel generator and completely go off grid on hamster power alone. No, really very nice

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    msurguybobby sissom

    Reply 6 years ago on Introduction

    Haha ! LOL, yep, the hamster power is the green power, go hamsters! =) I'm glad this is helpful!

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    msurguyDrakekay

    Reply 6 years ago on Introduction

    Wax melts at temperature about 65 C (150 F) so it will for sure melt in hot boiling water. You can also recover some of that wax and use it to make your own candles.