CMPT

[z.monkey]

Then we glue down the top keeper...

[z.monkey]

I need to have a small hole to feed through the polar coil wire.  I used a piece of small heat shrink,  shrunk around a piece of wire.  Then drilled an appropriate hole all the way through the keepers, and into the plywood form.  This should maintain a small space so I can later feed through the wire for the polar coil...

[z.monkey]

I trim off the remaining stub that is above the keeper and add the other plywood form to the winding jig.  Then I use more fender washers and cut washers to distribute the clamping force better around the winding jig.  I torqued the assembly together very tightly, maybe 25 Ft/Lbs. Tight...

[z.monkey]

I want the jig to be as rigid as possible when winding.  If the equatorial coil keepers flex they will bow outward.  The coil will be injected with epoxy as it is being wound.  As the wire accumulates in the jig it will put pressure on the equatorial coil keepers in an outward direction and the plywood forms are there to prevent the plastic equatorial coil keepers from bowing outward...

Here is the winding jig on the drill, clamped to the bench...

[z.monkey]

I used a 5 minute epoxy with one of those mixer tubes, and this is where the fail happened.  Haste  makes waste.  I like using 5 minute epoxy for a lot of things, and even in this coil it worked great in a lot of places.  But, winding this equatorial coil took a couple minutes longer, Fail!  It took a solid two  weeks to get to this point, and as soon as I cracked open the jig it was Fail...