Endcaps for the OneTesla TS Tesla Coil

thingiverse

Using cut pieces of acrylic as endcaps led to a disastrous case of internal arcing that almost destroyed my transformer. In all likelihood, most of the problem was due to the wires slipping inside the secondary and finding little resistance within. The original setup also created shear points between the acrylic and the PVC of the secondary, causing the wire to snap easily if twisted or pushed in incorrectly. To solve this issue, I created endcaps that can be installed into the transformer while still giving access to the bolt where the wire enters. This also kept metal out of the tube. This solution seems to work exceptionally well. These parts were created using SolidWorks as a test run. This was my first attempt, and tolerances might not be perfect, but they worked for me. Some parts needed to be shaved down, but it wasn't a challenging process. I'm extremely pleased with the results of this, my first project like this. Instructions: 1. Print 2 copies of Endcap.STL and Center_Plug.STL. 2. Print one copy of Bottom_Plate.STL and Top_Plate.STL. You should now have two bolts that go into the endcap. Plug the endcap with the center plug. Insert the wires from the endcap into the groove and bolt them down. Then, place the plates on the ends. There are indentations for the holes on the endcaps to keep it from spinning. The bottom plate has extra grooves for the screw holes to prevent it from turning. The top plate is smooth and fits directly against the toroid.