oneTesla Tesla Coil Top Load Toroid

thingiverse

For those using this on a homemade tesla coil or secondary, the inner (minor) dimension is 70mm and the outer (major) dimension is 150mm (40mm toroid thickness). Wall thickness is 2.5mm, and each disk in the center is 1.25mm thick for an assembled total of 2.5mm as well. The hole in the middle is sized for an m6 bolt. The toroid is centered on the mounting plane. oneTesla was having issues with their manufacturer, so they sent me the kit without the top load to get started on while I waited for them to send the top load. Well I didn't want to wait, so I created this. It should be about the same size and shape as the one that comes with the kit. The one stl file is both the top and bottom half. To assemble, I used super glue to fix each half together then used air duct repair tape (aluminum tape) from lowes to cover the entire outer surface. Make sure you get the right tape, the kind with the writing on it probably has some type of coating on the surface which will not work. The kind I used is literally thin aluminum with an adhesive backing. I cut each strip in half to make a piece that was about 6 inches by 1 inch, and used those for the outer toroidal shape. I then placed a square in the middle flat disk to finish it up. Cut out the bolt hole, and it's almost finished. After finishing taping over the entire surface, I used the handle of an exacto knife to smooth any bumps and creases. The smoother it is, the better. Don't freak out if your tape job has imperfections while you are doing it, as it smooths out surprisingly well and easily. To mount to the secondary, you could probably get away with just the stock nut. On mine, I used two fender washers, one on each side, to sandwich the top load and create a good contact between the secondary bolt and the aluminum surface. Use as normal with the copper break out point, and watch the sparks fly! Fully tested up to full power at all frequencies and works perfectly.