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Transformer repair - Printable Version

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Transformer repair - TV MAN - 01-22-2025

Guys, I could use a little advice on a transformer repair. I'm restoring a small TV, and found a bad solder connection one of the leads. I opened the transformer and was delighted to find I had continuity from the winding leads throughout the rest. I made a repair with a new wire. My question, what would you guys recommend to use to secure the repair & prevent movement of the wire and possible breakage? Here's a pic:

   

RE: Transformer repair - morzh - 01-22-2025

They use some tape (kinda like the medical, cloth-based sticky tape), and then the paper or film wrap.

RE: Transformer repair - GarySP - 01-22-2025

You could try a hot glue gun and re-seal the cut as well as affix the new wire to the side of the coil. Pray you never have to re-open it!
Take care and BE HEALTHY! Gary

RE: Transformer repair - TV MAN - 01-22-2025

I'd thought about some clear epoxy. I need something that will stick and not damage the connection, conduct, arc or anything. I think I read that silicon would corrode. I don't really want to bury the connection because I might not be able to get enough wire to redo the connection if ever needed.

Edit: Just saw this.
Gary, I'd thought of hot glue but kinda ruled it out thinking it could get hot enough to soften. Good idea to affix the wire on the side of the transformer. It's solid conductor so it will bend and stay bent.

RE: Transformer repair - morzh - 01-22-2025

Tim

There is silicone RTV that specifically made for potting electronics, and is non-corrosive (so it does not smell like vinegar).
Mouser has them; We use RTV162.

https://www.mouser.com/ProductDetail/MG-Chemicals/RTV162-85ML?qs=sbrGYOVz3HeDc3Zk7MUnMg%3D%3D

Not cheap.

300ml is better price per ounce, but then it is more to pay.

RE: Transformer repair - GarySP - 01-22-2025

Epoxy and RTV are also good choices. The advantage of hot glue is that it is non-conductive, and can be remelted if needed. -Gary

RE: Transformer repair - radiorich - 01-22-2025

Hello TV man ,
Also to add to what morzh said about RTV I use Permatex Ultra Blue is a multi-purpose sensor-safe, low-odor, non-corrosive RTV gasket maker.

Sincerely Richard

RE: Transformer repair - morzh - 01-22-2025

Hot glue is good too; the only thing, you have to work quick and could get burned if trying to do it with your fingers. I do it all the time, but my fingertips have callouses and no fingerprints. Icon_smile
With RTV you can take yuour sweet time, sip on a beer....24hr full set.

RE: Transformer repair - TV MAN - 01-23-2025

Thanks guys for the tips! Not sure which direction I'm going with yet. Sounds like several options.

RE: Transformer repair - TV MAN - 01-25-2025

I tested the transformer and found it was working, which THRILLED me knowing this would be near impossible to source and may have ended my resto on this little TV. I ended up using some clear 2 part epoxy and carefully dabbed it on to secure the wire near the connection. It ran a little under the transformer wires, but did keep the actual solder joint open, so if ever needed, I have a chance at a 2nd repair. It might protect the small coil wire from breaking at the surface. I later bent the wire up as shown and laid on another round of epoxy, then put a piece of black tape over, tacked with epoxy to protect the repair (and me). Thanks for the advices and helping me to save this unobtainium transformer. Follow up on the TV thread.

RE: Transformer repair - radiorich - 01-25-2025

Hello Tim,
that is exactly what this forum is about helping others and items just like this that are almost impossible to find .

Sincerely Richard
P.S. I have to revisit a restoration today from 2021 silver mica issues.