How to Build an Inductor
An inductor is a device that concentrates the magnetic energy created by an electric current. An inductor is most commonly made by coiling wire around a hollow cylinder called a form. The form can then be removed, allowing the coil of wire to retain its shape. A very weak inductor may consist of only a wire with a metal bead or cylinder around the wire. The primary task in constructing your own inductors is ensuring that the coils of wire provide the desired electromagnetic characteristics.
Instructions
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1
Make a coil form. You can make a coil form from a section of PVC pipe with the desired diameter and length. Cut a pair of slots on opposite sides of the pipe that go almost all the way through the pipe. The width of the slots will depend on the diameter of the pipe but it will generally be at least 3/8 inch wide.
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Construct a support for the form. This may be a pipe or block of wood that has the same length as the form and is just small enough to fit inside the form. The purpose of the support is to keep the form from collapsing while you are making the inductor.
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3
Select the spacing cord. You may want to space the coils of very large wire manually and even out the spacing after you complete the coil. However, for most gauges of wire, you'll want to use a spacing cord to provide the desired spacing.
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4
Wind the coil. Attach the wire and spacing cord on one end and line them up so they are parallel along their entire length. Pull the wire and spacing cord taut and carefully begin wrapping them around the form. Once you have completed the coil, remove the spacer cord by unwinding it from the form.
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Build the ribs. Glue a pair of Popsicle sticks of appropriate length along the sides of the coil for support. The ribs may need to be longer or shorter than Popsicle sticks, depending on the size of the coils. Once the glue has dried, remove the form supports and squeeze the ends of the form together. This should allow you to slide the coil of wire off of the form. If you got glue on the form, you may need to cut the glue off of the form before you can remove the coil of wire.
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