Сентябрь 06 2010 07:14:14
DIY malicious stun gun
Boring part
Let's begin from the most boring and complicated part - making the transformers. Wounding them is typically very hard for beginners, but if you will carefully read and follow our instructions you should have no problems.

Voltage converter transformer
The first thing you need is a 22mm pot core . It consists of two "cups" with a bobin between them, and typically made from #77 ferrite material.

Take the bobin and wrap a secondary using #37 AWG or similar DOUBLE INSULATED enameled wire. Don't mention actual number of turns, just wrap as many as you can fit, leaving 1.5mm space on the bobin. It'll be even better if you carefully make "layers", placing some insulation between them. In this case you should get 6-7 layers totally.

Then wrap around some insulation, take #20 AWG wire and make 6 turns with CENTER TAP.

You can now assemble the core.


Output transformer
This is really boring part. But we have simplified this process also. We will use sectional topology instead of traditional layered. It requires no special materials and skills to make. For this, you will need 20mm PVC pipe like those used in "spud gun" but much more thinner. Just go to your local hardware store and ask... You need only 2" piece.

Then you should make sectional bobin from this. You can use special lathe machine or the following method. Take a drill and find any straight bolt that fits in. Fix the tube over it using insulation tape or something. Now you need a cutter tool, which can be made from a piece of steel plate approx. 2mm thick. Or something else, just use your imagination. Turn on the drill and begin to form sections. Your goal is 2x2 sections, e.g. 2mm high and 2 mm wide. After you finished with sections, take a knife or hacksaw and make longitudinal cut, 2-3mm wide, across all sections to let the wire run free from one to another. Then i suggest you to drink some beer ;-)

...Because here starts the most interesting. Take #32 AWG enameled wire, and wrap aroud all sections, from one to another. You can use drill, but don't let the wire overfill the secions, it's very important. Make an output lead at the beginning of wire. But don't do anything with the end yet.

Now you need to find ferrite rod of about 10mm diameter. This should be the same #77 material or better one, NOT just any rod from AM receiver! I don't know if it can be found in america or elsewhere, but in Russia this type of core in unavailable. So we invented some ways to get it. The first way is the use of salvaged TV FLYBACK TRAnSFORMER. In can be broken apart, then machinered to form a rod. This process is well shown on the pictures. Note how to break ferrite correctly.

Another way to make a rod is to use many ferrite rings glued together. it's an apropriate way, but not actually recommended.

Cover the rod with a layer of insulation and wrap 20-25 turns of #20 AWG wire, be sure to center the winding... ATTENTION! you should wrap in THE SAME direction as in secions, otherwise it will not work. Cover it with additional few layers of insulation, to have tight fit into bobin.

Then insert the rod into bobin, and CONNECT WINDINGS TOGETHER at one side. Ypu should get 3 output terminals instead of regular 4: input, ouput, and common leads.

In the final stage transformer is placed into cardboard box and then filled with melted paraffin. You should glue leads with the box to prevent wax leakage. Then transformer is placed under hot air stream, in example household heater on fan. This will cause all fuckin' air bubbles to come out and go fuck ;-) The box should be made with height reserves, because wax will collapse when cooling. This process concedes nothing to factory vacuum technology on quality of electroisolation, but it can be performed at your kitchen without problems ;-) The only thing that matters is paraffin quality. Look for a dark-brown colored candles because they're much stronger.

If you're done with the transformers you can continue reading further...

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