I basically sit down and analyze each step in the winding process and do one step at a time. One of my oddest situations was when winding an old ’63 Telecaster Rhythm bobbin. Normally the average DC resistance would be about 7.6 K DC resistance for the particular number of turns that I use. Each time I would wind the bobbin the coil would read 6.4 K or 6.8 K or 7.0 K instead of the 7.6 K I was looking for. After winding 3 or 4 coils with 43 Plain Enamel magnet wire, I decided to figure out what the problem was.

With the help of my microscope I found that as the turns increased in relation to the winding speed I was using caused the insulation to chip off the ends exposing the bare copper wire and the turns would short out. I realized the winding speed was to fast and I increased the distance or pitch between each turn. I also noticed the insulation was quite brittle on the magnet wire and as each turn was bent around the 3/16″ rod magnet it wouldn’t allow time enough for the magnet wire to form to the shape of the angle. I found that warming up the magnet wire in an oven to about 120 degrees softened the insulation and magnet wire allowing it to shape better to the radius of the magnet.