[Elecraft] On hand-twisting wires for bifilar windings...

[Michael Studer]

I use aircraft safety wire pliers.  It makes it ridiculously easy.
These pliers are specifically designed to twist 2 wires together at an
easily controllable rate of twist.
Aircraft Spruce sells them.  The economy version is $21. P/N 12-18900
www.aircraftspruce.com

Mike AB6CV



On Thu, 2 Oct 2003, Tom Hammond wrote:

> Hi Folks:
>
> Upon Dave, KK7SS', suggestion, I'm posting this message to the reflector
> for the possible benefit of newbie builders who are agonizing about how to
> get the proper amount of 'twist' into the wires they're winding for a
> bifilar-wound transformer, such as those used in all the Elecraft ATU's and
> the KPA100.
>
> Dave wrote:
>
> >Another question..
> >
> >For the KXAT1, T1 uses a pair of wires, twisted together at 4 tpi. Having
> >done this before, and having messed it up at least three times, do you
> >have a method than can be done by hand that works well??
> >
> >I'd use a drill, but my eldest boy borrowed it and (naturally) can't find
> >it. If not, I'm going to try by using the same method I use to braid my
> >daughters hair
>
> Heheh...
>
> Well, I'd already taught myself to do it long before someone else brought
> up the subject of using a drill motor... MUCH too easy for me anyway... If
> there's a difficult way to do it, I'll probably find it.
>
> The way I do it is to place both wires together, side by side and make a
> couple TIGHT twists at one end, and for no more than 1/2"-3/4" of the
> length. These are JUST to hold the wire ends together and they're CUT from
> the final product once it's been more properly wound.
>
> I ensure that each wire in as straight as I can easily make it, and I then
> hold the twisted end between my thumb and next two fingers with one wire
> extending back between the thumb and forefinger and the other wire
> extending back between the forefinger and the middle finger.
>
> Next, I grasp the twisted end with the other hand and continue twisting on
> it AS I pull it away from my fingers. This allows me to impart a measured
> twist to the wires out ahead of my fingers while allowing the free ends of
> the wires to UNtwist, in response to the twisting I'm doing up front.
>
> If you secure the untwisted wire ends, the twist you impart at the front
> will try to cause the loose wires to 'take a set' and this is something you
> don't want to happen. It's just like when the Boy Scouts used to make their
> own rope... if you've ever seen their rope-making machines, one end
> imparted the twist and then the twist was released at the back end.
>
> This method works great for me... been using it for a couple decades, I
> guess. It's a helluva lot longer to explain that it is to DO!
>
> Hope this helps.
>
> 73,
>
> Tom  N0SS
>
> p.s.
>
> Yes, you CAN use a drill motor to do the winding, but, generally, by the
> time you get the drill out and set up, I can have the wires all twisted by
> hand and I'm on to more building.
>
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