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Toroid winding cheat

torroid-winding-cheat

When you need a toroid the easiest source is often to wind it yourself. The problem being that placing a few hundred windings around a ferrite ring is a real drag, especially if you have to make several of them. This cheat developed by [Jim W.] will save a lot of time. He cuts the ring in half for the winding and reassembles it afterward.

Here you can see that he has half of the core mounted in a drill chuck. To get to this point he scored the ferrite before clamping half in a vice and whacking the extruding half with a block of wood and a hammer. He hasn’t found a perfect solution for scoring the material (a utility knife or a triangular file both work but have drawbacks). Leave a comment if you’ve got any bright ideas.

Once the core is in two pieces he used some copper pipe with one end flattened and bent to the shape of the ring segment. With it hot glued in place he takes it for a spin (shown in the clip after the break). Once the windings are done a bit of super glue recombines the halves. This sort of thing is great for monitoring power use.

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A different take on electric motor cars

[Craig Carmichael] has been hard at work on his electric hub motor for cars. Unlike typical electrical vehicles the plan is to bypass the transmission, differential, and everything else all together by connecting directly to the hub of the wheel. The goal of giving greater thrust and still allowing the use of a gas engine if need be.

There’s really too much detail for us to even begin to try to explain the entire project in a short recap, but [Craig] builds the entire motor (from magnets to coil windings) and wires his own controller (from schematic to finished PCB), all while documenting the process thoroughly for those wishing to make their own.