Results 1 to 25 of 25

Thread: Running out of wire when winding

  1. #1
    Member
    Join Date
    Jul 2015
    Location
    Petaluma, CA
    Posts
    21
    Thumbs Up/Down
    Received: 0/0
    Given: 0/0

    Running out of wire when winding

    I just finished winding my last coil and noticed the wire left on the spool is very low. I was wondering what procedures other people use when running low on wire. Some possibilities come to mind:

    • Put aside the old spool and use new one. Possibly the experienced eye can tell when there's not enough wire left to complete a coil.
    • Continue to wind with the old spool and splice if it runs out.
    • If the wire runs out, remove it from the bobbin and start over with a new spool.


    Since I'm relatively new to winding, I haven't developed the "feel" for how much wire is left. My plan presently is to take the chance and wind another coil. Since the next bobbin planned is very small, it may make it. If not, I'll get the chance to see a bare spool, which will give me an idea of how much wire is left going forward.

    Thanks for any shared thoughts.

    Bob

    0 Not allowed! Not allowed!

  2. #2
    Member
    Join Date
    May 2017
    Posts
    33
    Thumbs Up/Down
    Received: 1/0
    Given: 0/0
    If you know the weight of naked spool (a lot of wire retailers use standardized spools), you can weigh yours, subtract the naked weight, and, from the original specs from the seller, work out the length of the remaining wire, give or take a few yards...It saves the trouble of having to start over if you run out too soon.

    0 Not allowed! Not allowed!

  3. #3
    Supporting Member mozz's Avatar
    Join Date
    Oct 2015
    Location
    NEPA
    Posts
    540
    Thumbs Up/Down
    Received: 17/0
    Given: 20/0
    Measure the resistance of the leftover wire and estimate compared to a finished coil. I have spliced before with no problems. Just make sure you scrape the insulation off and solder good.

    0 Not allowed! Not allowed!

  4. #4
    Member
    Join Date
    Jul 2015
    Location
    Petaluma, CA
    Posts
    21
    Thumbs Up/Down
    Received: 0/0
    Given: 0/0
    Interesting, hadn't thought of working off of weight of the spool. That'll take a small bit of research to see how practical. DC resistance sounds good, if the inside end of the wire can be reached without unwinding the spool. I'm not at my shop presently, so can't inspect it for access to the end. I'll check first thing Monday. Thanks guys for the ideas!

    0 Not allowed! Not allowed!

  5. #5
    Senior Member Jim Darr's Avatar
    Join Date
    Feb 2009
    Location
    Southeastern US
    Posts
    295
    Thumbs Up/Down
    Received: 0/0
    Given: 0/0
    Quote Originally Posted by bmcd View Post
    I just finished winding my last coil and noticed the wire left on the spool is very low. I was wondering what procedures other people use when running low on wire. Some possibilities come to mind:

    • Put aside the old spool and use new one. Possibly the experienced eye can tell when there's not enough wire left to complete a coil.
    • Continue to wind with the old spool and splice if it runs out.
    • If the wire runs out, remove it from the bobbin and start over with a new spool.


    Since I'm relatively new to winding, I haven't developed the "feel" for how much wire is left. My plan presently is to take the chance and wind another coil. Since the next bobbin planned is very small, it may make it. If not, I'll get the chance to see a bare spool, which will give me an idea of how much wire is left going forward.

    Thanks for any shared thoughts.

    Bob
    My 2 cents. Splice, Splice, Splice...but splicing, if not done properly, can cause problems down the road with a break in continuity. If your going for A #1 quality you probably want to give notice to the buyer and sell it at a slight discount.

    0 Not allowed! Not allowed!
    =============================================

    Keep Winding...Keep Playing!!!

    Jim

  6. #6
    Supporting Member
    Join Date
    May 2006
    Location
    PDX
    Posts
    3,215
    Thumbs Up/Down
    Received: 4/0
    Given: 2/0
    See thread on low impedance pickups...

    0 Not allowed! Not allowed!

  7. #7
    Senior Member
    Join Date
    Sep 2011
    Location
    Minneapolis
    Posts
    284
    Thumbs Up/Down
    Received: 0/0
    Given: 0/0
    There seems to be two schools of thought on splicing. A: It's fine if done right. B: Never sell a spliced coil.

    I'm in camp B.

    You can weigh the wire or just do it enough that you'll know there's not enough on the spool to finish a coil. Save that spool for r&d.

    0 Not allowed! Not allowed!
    Last edited by jrdamien; 08-18-2017 at 07:01 PM.

  8. #8
    CNC Trial by Fire kayakerca's Avatar
    Join Date
    Jul 2011
    Location
    Ottawa, CANADA
    Posts
    758
    Thumbs Up/Down
    Received: 0/0
    Given: 5/0
    Quote Originally Posted by jrdamien View Post
    There seems to be two schools of thought on splicing. A: It's fine if done right. B: Never sell a spliced coil.

    I'm in camp B.
    Camp "B" here as well.

    0 Not allowed! Not allowed!
    Take Care,

    Jim. . .
    ____________________________________________________
    In the immortal words of Dr. Johnny Fever, “When everyone is out to get you, paranoid is just good thinking.”

  9. #9
    Member
    Join Date
    Jul 2015
    Location
    Petaluma, CA
    Posts
    21
    Thumbs Up/Down
    Received: 0/0
    Given: 0/0
    Thanks for everyones opinions. On my last coil I ran the wire down so the core of the spool is showing. I now can use this as a visual reference going forward. I measured the inside diameter of the spool and can compare that to others when wire is running low. I could also do a calculation to roughly determine how many turns are left on the spool and very approximate wire length left. Not an accurate number, but a ballpark figure. I was hoping the coil estimator would give wire length of a given coil, but I didn't see that feature. I'd have to do a similar calculation to determine length needed to wind the intended coil. I'll have to think on this a bit.

    In the meantime, since I have an empty spool as a reference, developing a feel for how much wire is left is a good "seat of the pants" approach. I generally don't like splicing, but sometimes it can be appropriate when doing R&D, so I'd have to say I'm in Camp B as well.

    0 Not allowed! Not allowed!

  10. #10
    Member
    Join Date
    Jul 2015
    Location
    Petaluma, CA
    Posts
    21
    Thumbs Up/Down
    Received: 0/0
    Given: 0/0
    David, I'll take a look at the low impedance thread. Presently 8 pages long, so will take a while! Thanks for the reference.

    0 Not allowed! Not allowed!

  11. #11
    Supporting Member
    Join Date
    May 2006
    Location
    PDX
    Posts
    3,215
    Thumbs Up/Down
    Received: 4/0
    Given: 2/0
    bmcd,

    Sorry that was a joke or at least trying to be. That said the thread is fascinating but uses a different wire gauge so not really relevant.

    0 Not allowed! Not allowed!

  12. #12
    Woodgrinder/Pickupwinder copperheadroads's Avatar
    Join Date
    Jun 2009
    Location
    Iceburg Alley ,Newfoundland,CAN
    Posts
    2,067
    Thumbs Up/Down
    Received: 8/0
    Given: 5/0
    I make a pickup that I start out winding with 42 gauge & splice a smaller gauge on & keep winding .

    0 Not allowed! Not allowed!
    "UP here in the Canada we shoot things we don't understand"

  13. #13
    Senior Member
    Join Date
    Nov 2006
    Location
    Sacramento, CA
    Posts
    503
    Thumbs Up/Down
    Received: 0/0
    Given: 0/0
    How did the 2 wire gauges affect the sound?

    0 Not allowed! Not allowed!

  14. #14
    Woodgrinder/Pickupwinder copperheadroads's Avatar
    Join Date
    Jun 2009
    Location
    Iceburg Alley ,Newfoundland,CAN
    Posts
    2,067
    Thumbs Up/Down
    Received: 8/0
    Given: 5/0
    Quote Originally Posted by Richard View Post
    How did the 2 wire gauges affect the sound?
    The same way i anticipated it would.

    0 Not allowed! Not allowed!
    "UP here in the Canada we shoot things we don't understand"

  15. #15
    Old Timer
    Join Date
    Feb 2010
    Location
    Just south of Bawlmer, Merlin
    Posts
    2,360
    Thumbs Up/Down
    Received: 74/1
    Given: 53/1
    Didn't the skinnier wire choke off the sound?
    I'd be afraid of electrons backing up at the splice until the whole thing exploded.

    0 Not allowed! Not allowed!

  16. #16
    Woodgrinder/Pickupwinder copperheadroads's Avatar
    Join Date
    Jun 2009
    Location
    Iceburg Alley ,Newfoundland,CAN
    Posts
    2,067
    Thumbs Up/Down
    Received: 8/0
    Given: 5/0
    I bottle necked the electrons buy sub dating the electrons between 2 pieces of a special tape . after 6 years it's still holding . with zero Radiation or any increase molecular activity .

    0 Not allowed! Not allowed!
    "UP here in the Canada we shoot things we don't understand"

  17. #17
    Old Timer
    Join Date
    Feb 2010
    Location
    Just south of Bawlmer, Merlin
    Posts
    2,360
    Thumbs Up/Down
    Received: 74/1
    Given: 53/1
    Quote Originally Posted by copperheadroads View Post
    I bottle necked the electrons buy sub dating the electrons between 2 pieces of a special tape . after 6 years it's still holding . with zero Radiation or any increase molecular activity .
    I have no idea what that means, but I like it.

    0 Not allowed! Not allowed!

  18. #18
    Supporting Member John_H's Avatar
    Join Date
    Jul 2006
    Location
    Las Vegas Nevada
    Posts
    958
    Thumbs Up/Down
    Received: 12/0
    Given: 5/0
    Quote Originally Posted by copperheadroads View Post
    I make a pickup that I start out winding with 42 gauge & splice a smaller gauge on & keep winding .
    I do this on a couple of designs.

    There's nothing wrong with a proper splice. If I have a spool of wire that's almost empty, I'll set it aside, and use it for my own stuff, or a tapped coil.

    0 Not allowed! Not allowed!

  19. #19
    Senior Member Jim Darr's Avatar
    Join Date
    Feb 2009
    Location
    Southeastern US
    Posts
    295
    Thumbs Up/Down
    Received: 0/0
    Given: 0/0
    Quote Originally Posted by copperheadroads View Post
    I bottle necked the electrons buy sub dating the electrons between 2 pieces of a special tape . after 6 years it's still holding . with zero Radiation or any increase molecular activity .
    Ah...the "special tape" and using "2 pieces"...I never thought of that!!! It must be NOS tape from the mid-fifties, right?

    0 Not allowed! Not allowed!
    =============================================

    Keep Winding...Keep Playing!!!

    Jim

  20. #20
    Woodgrinder/Pickupwinder copperheadroads's Avatar
    Join Date
    Jun 2009
    Location
    Iceburg Alley ,Newfoundland,CAN
    Posts
    2,067
    Thumbs Up/Down
    Received: 8/0
    Given: 5/0
    Quote Originally Posted by Jim Darr View Post
    Ah...the "special tape"!!! It must be NOS tape from the mid-fifties, right?
    It's a rare blend of Scotch .

    0 Not allowed! Not allowed!
    "UP here in the Canada we shoot things we don't understand"

  21. #21
    ToneOholic! big_teee's Avatar
    Join Date
    Jun 2010
    Location
    Mid-South USA
    Posts
    10,151
    Thumbs Up/Down
    Received: 96/21
    Given: 102/9
    Rare aged Scotch tape, has that nice amber patina look!

    T

    0 Not allowed! Not allowed!
    “When you find yourself in a hole, quit digging.” WILL ROGERS

    Keep Rockin! B_T
    Terry

  22. #22
    Supporting Member
    Join Date
    May 2006
    Location
    PDX
    Posts
    3,215
    Thumbs Up/Down
    Received: 4/0
    Given: 2/0
    I like to use two thicknesses of scotch tape for each splice.

    0 Not allowed! Not allowed!

  23. #23
    Pickup Maker David Schwab's Avatar
    Join Date
    May 2006
    Location
    Staten Island, NY
    Posts
    10,946
    Thumbs Up/Down
    Received: 2/0
    Given: 3/0
    I splice. I use a small length (.25") of tined hookup wire... same wire I use to connect the start and finish of the coils. I wrap about 10 turns of each end of the wire, and then solder it. I then use my meter to check from that splice to the start wire. If it reads good, I cut off the excess tinned wire, then tape up the splice with thin masking tape, lay it on the coil, and continue winding.

    I've done this a number of times with no ill effects.

    But... I only spice if I wasn't expecting a break or end of roll. If I see the roll is near the end, I use a new roll.

    0 Not allowed! Not allowed!
    It would be possible to describe everything scientifically, but it would make no sense; it would be without meaning, as if you described a Beethoven symphony as a variation of wave pressure. — Albert Einstein


    http://coneyislandguitars.com
    www.soundcloud.com/davidravenmoon

  24. #24
    Member
    Join Date
    May 2017
    Posts
    33
    Thumbs Up/Down
    Received: 1/0
    Given: 0/0
    ...and keep the old one for the next Filtertron!

    0 Not allowed! Not allowed!

  25. #25
    Member Alberto's Avatar
    Join Date
    May 2015
    Location
    Italy
    Posts
    82
    Thumbs Up/Down
    Received: 2/0
    Given: 2/0
    Quote Originally Posted by David Schwab View Post
    I splice. I use a small length (.25") of tined hookup wire... same wire I use to connect the start and finish of the coils. I wrap about 10 turns of each end of the wire, and then solder it. I then use my meter to check from that splice to the start wire. If it reads good, I cut off the excess tinned wire, then tape up the splice with thin masking tape, lay it on the coil, and continue winding.

    I've done this a number of times with no ill effects.

    But... I only spice if I wasn't expecting a break or end of roll. If I see the roll is near the end, I use a new roll.
    Same here

    0 Not allowed! Not allowed!

Thread Information

Users Browsing this Thread

There are currently 1 users browsing this thread. (0 members and 1 guests)

Similar Threads

  1. Wire Manufacturers recommended winding tension ?
    By copperheadroads in forum Pickup Makers
    Replies: 3
    Last Post: 06-03-2012, 05:58 AM
  2. Winding heavy gauge (#36) wire
    By Mark Hammer in forum Pickup Makers
    Replies: 6
    Last Post: 04-10-2012, 02:05 PM
  3. HQ Pickup winding wire from AndryPickupParts team
    By MrCandy in forum Pickup Makers
    Replies: 21
    Last Post: 08-12-2011, 10:56 AM
  4. Hand-winding using wire from another pickup...
    By cryptozoo in forum Pickup Makers
    Replies: 0
    Last Post: 01-07-2009, 01:03 AM
  5. Does hand winding mean hand on the wire?
    By JGundry in forum Pickup Makers
    Replies: 117
    Last Post: 11-11-2007, 02:20 AM

Bookmarks

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •