In keeping with the thrust of
this site, the intention is to be generally informative rather than
prescriptive. If you have researched suppliers, supplies, and
components (as suggested in the previous section), you should have a
range of options to develop when you arrive at the planning stage.
Perhaps you might even trial some ideas by way of 'prototyping'.
However, even before we discuss assembly, I
should emphasize the worth of a good drawing. Drawings (plans), can
reveal unforeseen problems, and raise design issues such as placement
and fitting of components, and assembly sequences. Regardless of
your drafting abilities - DON'T under-estimate the value of committing
ideas to paper - whether simple sketch plans, or full sized working
These have often saved me a cut in the wrong place - and time too!
The fitting of axles,
spindles, pulleys and faceplates should be done to close tolerance and
'fit'. The mounted pickup must rotate smoothly and 'on centre'. In some
cases this will require the faceplate to be 'dressed' to remove any
wobble - ideally on a lathe. Don't forget to wear a dust mask (for
wooden face plates) during this operation and fit and fix firmly.
and tolerances require ongoing checks, along with belt tension, machine
lubrication, and electrical checks. Some type of adjustable 'limiter'
assembly, to prevent wire overshooting the bobbin limits will prove
advantageous. My own design for adjustable acrylic limiters has served
'Direction of rotation' issues
will come into play for both winding and counting (if mechanical). All
my machines were specifically designed to rotate 'top going' (top
of spinning coil rotates away from the operator). I feel I can see the
building coil and wire 'tracking', more clearly this way, but the
rotation can work well if you have no choice. Put in the simplest
this comes down to circumstance, personal choice, and what you get
Except where indicated, most
of my machines are designed for hand guiding the wire onto the
spinning bobbin. This method best serves low production/multi-type
winding. Auto traversing (one method is outlined in Jason Lollar's
has greater application where higher volume, one-of-a-kind winding is
I like to control tension by
hand on most of my machines, however, 'set and forget' tensioner
ideas can be drawn from sewing machine devices. On my 'auto traversing'
unit, I use two felt lined aluminium discs that can be tightened
via a bolt. A numbered guitar knob fixed to the top of the bolt,
indicates a 'reading'. Coil wire passes through tensioner 'off centre',
meaning between the central bolt and the outer edge of the disc.
Sewing machine type
foot controllers will accumulate some heat buildup during operation,
and a 'machine kindly' approach is needed to keep this at a minimum
during operation. I prefer pedals with a plastic (insulated) outer
and avoid metal types. All wires, plugs, and connectors should be
for sound insulation, and safe location away from moving parts.
Mindful of the warnings that follow, I
that the would-be constructor undertake some prior training to deal
with electronics assembly issues. If necessary, refer electrical
to a qualified technician.
'Work Safely-Wind Safely'
electricity is a potentially fatal phenomenon. No person should embark upon any electrical work
without adequate instruction, knowledge and/or supervision. At all
times, the constructor must be mindful of the possible hazards and
observe all safety precautions/procedures.
Electrical work MUST be executed to a
professional standard and comply with local regulatory provisions.
Winding can be tiresome on the eyes. You should work
under good lighting conditions and rest frequently.
Consider using a headband magnifier (or
similar sight aid) for
Safety glasses (spectacles) are recommended where appropriate to the
task in hand.
Associated work, including wood and metal
work, may involve other hazards which should be addressed appropriately
by - protective clothing and/or
equipment, machine guarding, fume and dust extraction, safe materials
handling and storage, noise abatement, etc.etc. All workshop safety
practices and protection should be employed.
'Work Safely -Wind Safely'
While I endorse careful
adherance to all appropriate safety guidelines and safety precautions,
I cannot/will not be responsible for undertakings (or resulting
consequences) by any person working with designs, equipment, materials,
skill levels, wiring codes, and/or environmental circumstances outside
of my knowledge/awareness and/or beyond my control/supervision.
In this regard, the intending
constructor/builder MUST assume ALL risk and liability associated with
his/her original project/s.
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