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Updated 12.31.05

Winding the RS Theremin Coils
 
Stop Laughing!   This box method keeps the process organized

What's Needed for a 270 uh coil:

The coil form, Schedule 40  3/4" deep socket
You can use the standard shorter socket because the handles give you a method of holding the form.

Two 4" pieces of 3/4" sprinkler pipe (handles)

2'  piece of 1/2" PVC also used for Lev's Antenna

Plastic rod for the wire spool, cut off a coat hanger.

My cardboard box is the type reams of paper come in with a lid.

This box is also used to mount your theremin on when "tuning the coils" to get it away from the table surface.

This box is used to store all your left over materials when the project is finished.

Washing your hands will give you better grip on the wire or wear a disposable latex glove.

The first 50 out of the 100 turns of wire can be seen in this photo. Turn 25 in the middle is the pulled out Tap which is twisted and soldered.

The winding 50 wire is extended out on the right side. Burn a 1.5" section of enamel off near the form with a butane lighter. Clean the wire with a kitchen scrubber then loop & twist the center tap, then solder the twist. This prevents untwisting when pulling on the wire for the balance of the wire wraps.

Coil Making Components

Radio Shack Wire 278-1345 B - You only need the 50' spool of the Red #30 gauge wire (A.W.G. Metric 0,2540)

Everything below is at Home Depot

C482-007 Schedule 40  3/4" deep socket coupling (3"long) @ .59 each. Lowes does not carry these - < Note

12.31.05
You could use two of the standard 2" short 3/4" sockets. The handles in the above photo give you a method for holding the wire coil form. The total of 100 turns of wire 270 uh are about 1.15" (2.8 cm) in width. Start winding about 1/8" from one side which will leave room for a mounting bracket on the opposite side which will be the tuning screw side of the form. You should add all three center taps to both coils so you don't run into a mounting direction problem later on.

C449-007 Schedule 40  3/4" End Plugs

¼-20 coupling nut on the wall near the threaded rod in orange pack of 3
Not used on the Salt Coil - Instead use a ¼-20 tee-nut as seen in the bottom salt photo.

¼-20 x 3" Brass Screw - not used on the Salt Coil - Instead use ¼-20 x 2" 

1" Conduit Clamps These are found in bags of 5 in the electrical conduit section.
Home Depot brand is Powerline 5133738B

Foam Tape - 1/2" wide double side adhesive use to secure the wire wraps and hold the coil in the clamp.
Remove the enamel from the wire before soldering