k4900 width coil replacement "please verify"

I was just messing with some of these this past week. Out of like 4 chassis, 2 had coils that could adjust but one of them was all the way at the bottom; while adjusting it, the ferrite core cracked, expanded, and then it got stuck. That is my theory and why it is unlikely you can get one "unstuck".

Anyway, I didn't try this and it is not ideal, but mounting a g07 coil (not exact inductance range but close) off board, like a k4600, could be a less expensive solution.
15k startup plus first run ?? at $25 per coil ..only need to sell 600 of them to be profitable. Yikes. I would probably buy 10 . Does sound like a possible go fund me project (that I don't want to do :) )
actually the g07 coil isn't even close to the inductance of the k4900/k4600 as the g07 is 72uh-211uh and the k4600/k4900 is 62uh-359uh so the WG ending -003 for the k7500 would be much closer as its 50uh - 420uh. go fund me projects are stupid and people should learn how to take some risks themselves and some hard work instead of waiting with their hands out for people donating to their laziness especially when they don't have skin in the game makes them more prone to letting life interfere with production. go fund me should be to help someone having a tough run in life and not for lazy people to expect others to put up all the risk for new products which i will bet there are more projects that never get off the ground and fail or just quit early on to never be seen or heard from again because there is no skin in the game. i have already done all the work on these and simply when i find someone to create the bobbin designs i have and test a couple to fine tune them with 3d printer then i will send them off to be made and i already have the cnc winding machine which i have made the k4600 coils but a different design i have will make production much easier then winding them on their original type of tubes.
 
Guess I hit a nerve which was not my intention. I can only offer encouragement and commitment to buy some from whoever does the hard part. @SCUBA King @DogP any other 3D print gurus?
 
Many of the people with the skills to make a decent design don't actually have the part in hand or don't want to take it out of one of their working machines.

A simple technical drawing of what you're looking for would go a long way. If it's a simple part, even a hand-drawn sketch on a napkin might be useful.

Someone who plans to make a 3D model replicating a part would either need at least that, or the part itself.
 
K4900 Monitor Width Coil Bobbin v9 v14.png

K4900 Bobbin M6 thread


K4900Bobbin.png
Here's a 3D printed one side-by-side with the original. I'll put a winding on the new bobbin this weekend and see if everything works as expected.
The only significant changes I made to the original are a full thread through the whole tube, rather than just little bumps. I also beefed up the top slightly as the walls were a bit thin.
 
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K4900 Bobbin M6 thread


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Here's a 3D printed one side-by-side with the original. I'll put a winding on the new bobbin this weekend and see if everything works as expected.
The only significant changes I made to the original are a full thread through the whole tube, rather than just little bumps. I also beefed up the top slightly as the walls were a bit thin.
very nice.
 
I put windings on a couple of them to see how that would go. They're quite easy to wind.
The legs and ferrite transferred easily from an original to one of them.
The slug moves easily with an adjustment tool, but it's not loose in there either.
I ran a couple amps through it for an hour and it got up over 250F without it doing anything alarming.

Does anyone know how hot they run normally?

IMG_1250.png
 
My old Sencore meter is giving nonsensical inductance readings, so I can't compare the range with an original just yet.
I've ordered a new meter from Keysight. I'll do more with them when I get it.
I'll try installing one in a monitor, too. I want to know how hot it runs.
 
My old Sencore meter is giving nonsensical inductance readings, so I can't compare the range with an original just yet.
I've ordered a new meter from Keysight. I'll do more with them when I get it.
I'll try installing one in a monitor, too. I want to know how hot it runs.
k4900 coil inductance range is about 62uH to 359uH
 
k4900 coil inductance range is about 62uH to 359uH
Thank you.
I did get my new LCR meter, which appears to give reliable inductance readings.
I'll directly measure a couple original coils with my particular setup to get a sense of what target range I need to reproduce.
I did a quick measurement and what I'm getting now is a little on the high side, but not too bad. I think it would work reasonably as it is, but I'll tweak it a bit more when I have some time off from my real job.
 
The legs and ferrite transferred easily from an original to one of them.
@Glorp I think it is awesome you are doing this but are you providing the design to @security0001 so he can produce? I am wondering where the replacement cores will come from as the broken ones typically have a cracked core.
 
@Glorp I think it is awesome you are doing this but are you providing the design to @security0001 so he can produce? I am wondering where the replacement cores will come from as the broken ones typically have a cracked core.
Yes sourcing the ferrites will be a problem if you want to make a complete replacement.
It's probably pointless.
 
@Glorp I think it is awesome you are doing this but are you providing the design to @security0001 so he can produce? I am wondering where the replacement cores will come from as the broken ones typically have a cracked core.
yes i have about a 600-1000 ferrite slugs left for the k4600 coils which will work for many. @Glorp if you do a slight modification to this one it would be possible to use it for winding new k4600 coils also. let me know if you want the details shoot me a PM or email me on our site and i would be happy to pay you something if needed for the modifications.
 
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