Little EBay Tesla Coil Gets An Upgrade

Like so many of the projects we feature, this one started with a cheap eBay module purchase. In this case, it was a little Tesla coil that made decent sized arcs but wasn’t quite good enough. The result was a super-sized solid state Tesla coil with better results and room to grow.

As [GreatScott!] discovered, the little eBay Tesla coil has a pretty neat design. The exciter is a Slayer circuit, a super simple one-transistor design. His reverse engineering revealed that the primary coil is simply a loop trace on the PCB under the secondary coil. Sadly, his attempt to replace the primary and reproduce the Slayer exciter resulted in anemic performance. What’s a hacker to do in that case except build a bigger coil? Much bigger — like “build your own winding jig” bigger. Twelve hundred secondary turns and an appropriately menacing-looking primary later, the results were — still anemic. It turns out the Slayer is just not up to the task. He turned to an inverter circuit that was previously used in a wireless energy transfer circuit, and we finally get to see a little of the Tesla coil magic. But wait! There’s more to come, as future videos will tweak the circuit and optimize the coil for better performance.

It’s no surprise that Tesla coils are a popular project around here, especially the musical kinds, from the tiny to the large. Music doesn’t seem to be on [GreatScott!]’s mind, though, and we’ll be watching with interest to see where he takes this build.

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Put Plasma To Work With This Basic Toolkit

Fair warning: [Justin Atkin]’s video on how to make plasma, fusors, and magnetrons is a bit long. But it’s worth watching because he’s laying a foundation for a series of experiments with plasma, which looks like it will be a lot of fun.

After a nice primer on the physics of plasma, [Justin] goes into some detail about the basic tools of the trade: high voltage and high vacuum. A couple of scrap microwave oven transformers, a bridge rectifier, and a capacitor provide the 2000 volts DC output needed. It’s a workable setup, but we’ll take issue with the incredibly dangerous “scariac” autotransformer, popularized by [The King of Random]. It seems foolish to risk a painful death mixing water and line current when a 20-amp variac can be had for $100.

A decent vacuum pump will be needed too, of course; perhaps the money you can save by building your own Sprengel vacuum pump can be put toward the electrical budget. Vacuum chambers are cheap too — Mason jars with ground rims and holes drilled for accessories like spark plugs. Magnets mounted below one chamber formed a rudimentary magnetron, thankfully without the resonating cavities needed for producing microwaves. Another experiment attempted vapor deposition of titanium nitride.

It’s all pretty cool stuff, and we’re looking forward to more details and results. While we wait, feel free to check out the tons of plasma projects we’ve featured, from tiny plasma speakers to giant plasma tubes.

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Hacked CCFL Inverter Becomes An Arc Lighter

[GreatScott!] needs to light off fireworks with an arc rather than a flame, because “fireworks and plasma” is cooler than fireworks and no plasma. To that end, he attempted to reverse engineer an arc lighter, but an epoxy potted high-voltage assembly thwarted him. Refusing to accept defeat, he modified a CCFL inverter into an arc lighter, and the process is pretty educational.

With his usual impeccable handwriting and schematic drawing skills, [GreatScott!] documents that his CCFL inverter is a resonant Royer oscillator producing a sine wave of about 37 kHz, which is then boosted to about 2400 volts. That’s pretty good, but nowhere near the 15 kilovolts needed for a self-sustaining arc across electrodes placed 5 mm apart. A little math told him that he could achieve this by rewinding the transformer’s primary with only 4 turns. After some testing, the rewound transformer was fitted back into the Royer circuit and with a few modifications the arc was struck.

It’s not a finished project yet, and we’re looking forward to seeing how [GreatScott!] puts this to use. For now, we’re grateful for the lesson is Royer oscillators and rewinding transformers. But if you’d rather hack an off-the-shelf arc lighter, there’s always this arc lighter pyrography pen, or this mini plasma cutter.

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Try Not To Look At This Giant Plasma Tube

Everybody loves plasma globes, but if you are like [zrgzhv], building them as large as possible is the challenge! Definitely a beautiful project, at 7 feet long and 1 foot in diameter, this monster tube makes an impressive display of plasma filaments that slowly move inside. Heck, they almost seem to be alive following the movements of his hand and it’s hard not to become mesmerized by the motion.

seven-foot-plasma-tube-thumbThis tube follows the same principle of operation as its smaller cousin, the plasma globe. Air is evacuated and the tube is filled with a mixture of noble gases, with the particular mixture being responsible for the color of the filaments. Then, high voltage AC is applied to an electrode, which causes the moving tendrils of colored light to extend from the electrode to the outer glass, a phenomenon known as glow discharge. In general, gas-filled tubes can have other uses such as lightning — in the form of fluorescent, neon and xenon lamps — or high power switching as in the thyratron tube, among other applications.

The tube has a weight of over 65 pounds, and needs 300 watts of power to operate from an also homemade power supply. In another video, you can see 10 tubes of different colors working at once. Plasma always makes a great attention-getter; another nice example of its use can be seen in this steampunk lamp which incorporates rotating contacts on the outside of the glass.

Hackaday Prize Entry: A CNC Plasma Table

CNC routers and 3D printers are cool, but the last time I checked, cars and heavy machinery aren’t made out of wood and plastic. If you want a machine that will build other machines, you want a CNC plasma cutter. That’s [willbaden]’s entry for the Hackaday prize. It’s big, massive, and it’s already cutting.

A plasma CNC machine isn’t that much different from a simple CNC router. [will]’s table controller is just a GRBL shield attached to an Arduino, the bearings were stolen from many copy machines, and your motors and drivers are fairly standard, barring the fact they’re excessively huge for a simple 3D printer.

The real trick up [will]’s sleeve is the controller interface. For this, he’s mounted a Raspberry Pi display, a big, shiny, red button, and all the associated electronics behind a beautifully rusty welded enclosure. This part of the build just sends gcode over to the GRBL shield, and is doing so reliably. Right now [will] is looking for some way to save, arrange, and queue jobs on the Pi, a problem that is almost – but not quite – the same job Octoprint does. A software for big, mean CNCs that spew exotic states of matter is an interesting project, and we can’t wait to see where [will] goes with this one.

Arc Lighter Become Plasma Pyrography Pen

Wood burning can be quite a striking art form, but who wants to be stuck using an old-fashioned resistive heating element to char wood? You could go with laser engraving, of course, but that seems to take too much of the human touch out of it. So why not try a mini plasma pen and blow torch powered by a fancy cigarette lighter?

Arc lighters are rechargeable electronic lighters that look like a tiny stun-gun, and [NightHawkInLight] has been coming up with some interesting hacks for them. In this case, he extended the electrode leads out and mounted them to a wooden handle. The spark gap is only about 2mm, but the resulting arc is plenty hot enough to char wood with considerable precision. You’ve got to work fast, though, or the high voltage will start finding interesting paths through the char, producing Lichtenberg figures. And if a micro-scale blow torch is a tool you need, [NightHawkInLight] has got that covered too – a small brass tube with a pinched-off nozzle hooked to an aquarium pump provides the pressure for that.

Might there be other applications for this beyond pyrography? Maybe soldering or desoldering? Of non-ESD sensitive components, naturally.

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Electric Compass For A Plasma Cutter

If you are a Maker space or individual lucky enough to own a Plasma Cutter, this electric protractor compass could be handy. The folks over at [MakeItExtreme] built this circle cutting tool to help cut circles and rings in thick metal sheets using their plasma cutter.

The whole thing is built around an electro-magnet, so the jig will only work with magnetic metals. There are not a lot of design details, but it’s possible to infer how to build one looking at the video and the photos on their blog. There’s a couple of nice hacks along the way. Since the electro-magnet is stationary while the rest of the jig rotates, the main mounting bolt had a hole drilled through it to help route the cable. The rotating protractor arm is made from a slab of aluminium and holds all the other parts together – the drive motor, the central hub and the plasma head. The motor used appears to be a 60rpm AC synchro motor. These types usually have an RC phase shifting network between the two coils to allow direction reversal. Friction drive is used to rotate the jig, with the friction coming from a pair of rubber tube bands attached to the electro-magnet and the motor drive hub. The plasma head holder has a rod-end with a roller bearing attached, acting as a caster wheel, ensuring the arc gap is maintained as the jig rotates. A few switches to activate the electro-magnet, motor forward / reverse and plasma enable complete the setup.

Their blog, and YouTube channel has a lot of other interesting projects that they keep building. Check it out.

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