Toroidal Inductor Wire - How important is the insulation thickness?

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Reverie

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I'd be very interested to know what suppliers you'd suggest.
Because you only need a few feet, I suggest you make your own by twisting together several strands of magnet wire. For example, 9 strands of 25.5 AWG magnet wire will give you 16 AWG. I think Percy Audio still has some Ohno Continuous-Cast copper magnet wire in stock. Chimera Labs used to sell the same wire cryoed for a reasonable price. That would give you the wire quality you are seeking. Otherwise, there are numerous sources for ordinary magnet wire, including Radio Shack.



Ah yes. That's a pretty good idea.  :D

Providing all is still in stock, Percy Audio has the following gauges:

AWG20  - 2.53 strands is the equiverlent CSA
AWG21  - 3.19 strands is the equiverlent CSA
AWG26.5 - 11.41 strands is the equiverlent CSA

Unfortunately, none of them appear to be a close integer match as far as thickness is concerned.  Thankfully, I have standard uninsulated wire of this kind, so could experiment until I got a practical design.

Any thoughts on which combination is best? I imagine AWG21 would be a comprimise between 'all-out-litz' and solid core, would involve a wind or 2 more if using 3 strands though.


jb

Any thoughts on which combination is best? I imagine AWG21 would be a comprimise between 'all-out-litz' and solid core, would involve a wind or 2 more if using 3 strands though.

When replacing solid core with multi-stand wire in a coil, in addition to using enough strands to get the equivalent cross-section area, you have to be able to get enough turns on the core. The multi-strand wire will usually be fatter than solid core and the choice of strand count, gauge, and twisting method will influence just how much fatter it will be. Because more strands will give a better packing density, I suggest 11 or 12 strands of 26.5 AWG, which gives a 16.2 or 15.8 AWG equivalent.

I have a feeling Percy’s claim of 26.5 AWG may be a typo. Vampire, the supplier, says the wire is 26 AWG and Chimera says 25.5 AWG. As far as I know, they’re all talking about the same wire. I have some of that wire from Chimera and, after scraping off the varnish, it measures 0.017” dia. or  about 25.5 AWG. I suggest you get some and try it.

Reverie

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Any thoughts on which combination is best? I imagine AWG21 would be a comprimise between 'all-out-litz' and solid core, would involve a wind or 2 more if using 3 strands though.

I have a feeling Percy’s claim of 26.5 AWG may be a typo. Vampire, the supplier, says the wire is 26 AWG and Chimera says 25.5 AWG. As far as I know, they’re all talking about the same wire. I have some of that wire from Chimera and, after scraping off the varnish, it measures 0.017” dia. or  about 25.5 AWG. I suggest you get some and try it.


Hey jb,

Just as I thought this was the problem finally sorted, when I went to ask Percy Audio about his stock, I was informed:

"26ga all gone

quite a bit of 21ga and 20ga left"


 :cry:


Looks like I'll have to ask on a few for-sale boards...

jb

Looks like I'll have to ask on a few for-sale boards...

Good luck! In the mean time I suggest you try the 21 AWG OCC magnet wire. Three strands twisted together will give 16.3 AWG equivalent and should pack well enough to get the required number of turns on the core.


jrebman

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Steve,

I'm interested in some of this silk tubing.  PM coming your way.

-- Jim