DIY Flapjack Coil Jig

[z.monkey]

Howdy,

Been having a hard time finding information about winding planar coils.  Now-a-days they are all printed on a circuit board in those very expensive DC to DC converters.  There are not many garage engineers out there that are dealing with these type of coils I guess...

So I decided to use a CD-ROM as the "substrate" for the coil.  The wire will be glued to the CD in the final form.  I needed a way to hold everything together until I could apply glue to it.  So the base is a piece of 3/8" plywood.  There is a center shaft which is a 1/4" machine screw.  I used some strategically place fender washers to be the inside wall for the windings, and also provides the correct spacing between the base and the holder arms.  The holder arms piece was originally plywood, but I found that it didn't have the structural rigidity that was required.  So I fabricated another piece out of 1/2" thick fiberglass board.  I would really like to make this out of aluminum, but that is mo $$$.  So far I build the entire thing out of scrap materials laying around the shop, so its free, right?

I'll post some other pictures later, after I get the coil glued together...

[broli]

Wow that's quite smart. Thanks for sharing.

[z.monkey]

Here is the finished Flapjack Coil...

[Yucca]

Very tidy result Z.Monkey! See you´ve got the in circuit debugger on the bench

[z.monkey]

I don't want any buggers in my circuits...

I have the primary built now too...

I'll take a picture when I get home...