Kevin said:
Okay. So you suggest laminating several cores together, then winding
the magnet wire around a form made of cardboard. It sounds a little
bit like a ball of junk. But I think you have convinced me. You know
that a large transformer can be a little expensive to tear apart.
I doubt that you need a transformer rated more than 1000 watts.
First you must determine the power that the new transformer is going
to handle.
There are many surplus transformers available, and the chances are
good that you can find one with a similar rating, which would mean that
you would not have to make your own winding form.
For E-I laminations, the total cross-sectional area = square root of
the power Times 0.290 .
If you only measure the center cross-section area, then double that
for the total.
And for cost, it pays to shop around; wierd voltage transformers at
times go for far less than standard voltages, as nobody can use the
wierdos.
Grab one and plunk it downatthe cash register and ask how much for
this hunk of metal.
If too much, leave it there and walk away...you may be called back and
given a better price.
Add in other stuff, maybe even really junky crap and call it a pile of
metal..