Re: [TCML] Sonotube Preparation

[Steve Ward <steve.ward@xxxxxxxxx>]

Tyler,

I only remove the outside paper, and leave the inside of the sonotube just
as it comes.  I figure they put the wax in there to keep the cardboard from
absorbing moisture from the concrete anyway.

Also, i do not coat the inside, just the outside.  I let some varnish wick
into the ends of the cardboard when im brushing it on, it seems to stiffen
up the material and make it less prone to falling apart any time soon.

I used to do a few coats of varnish on the tube with some sanding in
between, but the last 2 sonotube coils were just single coats of thin
varnish and then wind the coil on top.  Depending on the wire size, you may
need more or less surface preparation to avoid winding frustration.

Steve

On Mon, Jul 13, 2009 at 8:01 PM, Tyler Pauly <rpggod714@xxxxxxxxx> wrote:

>
> Do you use any coating on the inside?  Mine isn't so waxy on the outside,
> mostly on the inside.  And because it is ~66 inches long, I don't know if I
> could get all of the inner waxy layer out.  I suppose I could remove the
> outer layer, it would probably increase the amount of varnish absorbed.
>
> Thanks again,
>
> Tyler
>
>
>
>
>
> ----- Original Message ----
> From: Steve Ward <steve.ward@xxxxxxxxx>
> To: Tesla Coil Mailing List <tesla@xxxxxxxxxx>
> Sent: Monday, July 13, 2009 5:15:28 PM
> Subject: Re: [TCML] Sonotube Preparation
>
> Tyler,
>
> Having wound many coils on sono-tube, here is my method.
>
> 1) make sure the tube has been in a fairly dry place for awhile, if its
> soggy, throw it out and buy a new one ;-).
>
> 2) remove the outer layer of waxy paper with all the black ink printed on
> it.  Usually this will peel off carefully, if you are not so lucky you can
> use an orbital sander to rip it all off.
>
> 3) give the rough cardboard form a nice heavy coat of polyurethane varnish,
> the cardboard will soak it up real nice.
>
> 4) after the varnish dries, give it a little wipe down to remove any large
> pieces of dust or anything, and wind the coil.
>
> 5) i give my coils 1 coat of varnish right after its done.  I let this dry
> overnight, and the next day apply a good coat of pour-on epoxy (or more
> coats of varnish if you like).
>
> My sonotube coils have no problem hurling 10-12 foot sparks (4' tube).
>  They
> are nice and light weight, but they can be fragile.  I beef mine up with
> some internal baffles cut out of 3/8" plywood.  They are just a snug
> friction fit inside the tube, i use 2 baffles total (plus the 2 end caps,
> also plywood).
>
> Steve Ward
>
>
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