DIY Flapjack Coil Jig

[z.monkey]

Wow that's quite smart. Thanks for sharing.

Hey Broli,
I would like to say that I just threw the thing together and it all worked...

But, you know, engineering stuff never works like that.  I probably spent about two full days fabricating.  I probably spent like three weeks thinking about how to do this.  I remember seeing pictures of Tesla's"pancake" coils, but how did he manufacture them?  That is a big ass problem!  It takes a precision jig to make something like this.  Then you have to take the jig apart so that you can glue the substrate to it...

Maybe it will become easier with time...

[z.monkey]

I decided to use an Iron tube core...

[z.monkey]

This way I can mount it with out putting stress on the flapjack coil...

[z.monkey]

I'll need to build up a pedestal to support the core...

[z.monkey]

Make a pretty outline...