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Old 13th Aug 2017, 12:07 am   #7
joebog1's Avatar
Join Date: Jun 2015
Location: Mareeba, North Queensland, Australia
Posts: 700
Default Re: Toroidal choke failure

Another trick is to "break the grain" in the wire!!.
To do this you need some soft material like flannelette over an edge of your bench, several thicknesses deep.
Pull the wire tightly between your hands and rub it over the edge of the bench with a steep angle.
Turn the wire over and repeat this several times. The wire will soften and make it much easier to get through the core. It still requires some tension when winding though, especially the first few turns that you should try and get as flat as possible on the toroid.
Its fiddly but arranging the wire side by side on the first layer, and then laying the second layer in the troughs of the first layer will also help.
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