Here's just a quick look at the DT lighting coils we manufacture being wound. I'm learning video editing, so just a short attempt. Later we'll do one showing the whole process from the new cut laminates being assembled to the vacuum resin application process.

We use the same process for rewinds as well. Using a machine like this means we can make them as new, better in fact as materials have improved. Its quick too, which means we can keep the cost to our customers down!

Thanks for the video... Do you think you could make a good lighting coil if you wrapped some copper around that guys bracelets. Sorry had to say that when I saw his bracelets

Thanks for the video, never seen one wound before. Back in the day we'd just send them out & they'd come back ready to go but often wondered what the process was like. Always thought of it as a bit of a secret society!!. Great to watch thanks.

After being wound they go in to a vacuum tank where resin is applied under a low vacuum to pull it deep in to the windings, then they are cleaned and baked. That ensures the copper windings don't come loose.

Yes i did wonder about what happens to finish them off but guessed some sort of bonding coating. Could see a tray full sitting on the table waiting to go 'somewhere' so good to know thanks. Did i see these are 12volt or mistakenly thought maybe that? as can't find it now. All good. Thanks.

yes they are designed to run as 12 volt coils.

That machine can handle the much thicker wire needed for 6 volts so we can rewind those too.
Prepping and finishing is where the time is in rewinds, actually putting the copper on is done in under 2 minutes!

Sorry to come back again. Just watching closely [with one eye on tv to see if we have a change of government in nz] & where you join in & start again, is that different voltages [charge rates & ac direct lighting etc] like the original 6 volt would have had. Do you run it just through a rectifier or a reg/rect. Maybe that sounds a bit silly but anyway--thanks for posting. That coil looks like one for a later DT type not the old 3 coil early stator like mine [not that i need one, just nosey lol]. Thanks.

The coil will be regulated to the voltage regulators value, but the tappings provide different levels of power. The centre is for the head lamp, the end tapping charges the battery. The ratio between the two has to be right or the winding doesn't work right.

Where there is no regulator the windings have to be put back turn for turn and the right wire size, correct to 0.1mm. Get it wrong and it'll either not supply enough power for bright lights or it could blow bulbs depending on whats wrong.

And with this bit of kit we can check not only the full output but if the turns ratios are correct between the two parts. It also tests regulator rectifiers and stators. The stator is mounted on a test bed and the test unit will absorb the power and show exactly how much power the generator is cable of producing

Love it! Are you also making the Ign source coil?