We got a neon sign transformer in the mail for a Jacob’s Ladder project. Only it wans’t packaged right and the insulator on one side got crushed. The lug you attach ‘the sign’ to is still electrically solid, but that’s the only thing holding that part of the circuit to the rest of the transformer.
Is there a replacement or repair procedure I could use to fix it?
I’d actually prefer soldering or braising a new lug/insulator assembly as the old lug’s threads are kinda corroded.
I’m equipped and more than relatively qualified to do this, it’s just a detail I’m not up to speed on.
I was reimbursed for the transformer, so ‘It’s not worth it, buy a new one’ is also acceptable…it’d just be cool if someone said ‘go to insulatorsIsUs.com’ and buy a kit.
Nearly any decent insulating material should do. For a JL, you don’t really need mechanical strength. If I were doing it, I’d A) braze the electrical connections as you suggest and B) build a new insulator out of autobody fiberglass and resin. Cut it into strips and just wrap it around until it’s built up to size. You can even sand it and paint it when its cured.
I doubt it’s worth tracking down the correct insulator. I would use something like a shotglass, and drill a hole in the base, then use silicone to glue it to the body of the transformer.
That’s not a seriously large transformer, but these are.
And in turn, someone else will be along to post pictures of industrial substation transformers.
Well, large compared to most wall warts…and their output.
I’ve spent some time on the lathe making the stand-offs for the ladder out of brass. I’m planning on supporting the transformer in a wooden box, I figure wood and air are pretty good insulators and plan on using 220v romex and non-fluxed welding rod to complete things. The uprights will be protected from the uninitiated with plexiglass.
Really, the hard part will be making the wood box look as good as the rest of the parts.
They are copper, just a little tarnished, I’ll clean 'em up right purty.
The plan is to have a Frankenstien’s lab in the garage, there’ll be a rope chain across the front and the ladder will be a good 12-16 feet back, with an intermittent switch (it won’t be on full time, there’s an ozone and, uh, interference issue.)
