Re: Toroidal choke failure
Photo of the original would help!
It's unlikely to be a ferrite toroid, unless it is a common-mode choke. Iron dust or moly-permalloy powder, yes.
In the absence of a photo, is it a single-layer winding? Are start and finish turns pressed closely together? If so, maybe drop a wire gauge. It'll run slightly hotter but this may not be an issue.
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