The PHILCO Phorum
Transformer Rewire - Printable Version

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+--- Thread: Transformer Rewire (/showthread.php?tid=26132)


Transformer Rewire - dconant - 12-13-2025

Hello, I thought I would show how I rewire a power transformer.

Here I create some coils that I will use to splice the new wire on to the old transformer wires. I figure twisting the splice together creates too much movement of the existing wire. The less the better. Note two of the coils are a little bigger. The bigger ones will be used for the 6 volt winding. I use 20 gauge for all wires except the 6 volt winding which I use 18 gauge. To create the coils I wrap 7 turns of 22 gauge wire around a #14 gauge solid copper wire. I use #12 copper wire for the 18 gauge wire.  
   

Here I have attached the new 6 volt wire to the old by placing the coil over the old stripped back wire and then sliding the new into the coil. No twisting.
   

Here the 6 volt wire is soldered and ready for shrink tubing.
   

Here the 6 volt wire is completed as well as the 6 volt center tap. 
   

Here is my 6 volt center tap wire. I used a green marker as the tracer on the yellow wire since I don't have the proper wire. Should be green with yellow tracer. For the high voltage center tap it is yellow wire with red marker for the tracer.
   

Here is the finished transformer ready to go back in the radio. I have done several of these with no problems.
   

Hope this helps someone out. 

Dan

RE: Transformer Rewire - MrFixr55 - 12-27-2025

Nice idea and nice job on the transformer!

RE: Transformer Rewire - Jimradio - 12-28-2025

Very nice, I have seen this on Buzz 1151 YouTube video, great idea.

RE: Transformer Rewire - dconant - 12-28-2025

I have seen the Buzz1151 videos doing this. I figure I can do that too. I thought using the little coils of wire would minimize the chance of breaking wires deeper in the the transformer while keeping the wiggle of the wires at a minimum.

RE: Transformer Rewire - MrFixr55 - 12-28-2025

Someone either on this Phorum or one of the others posted a vintage ad from one of the parts jobbers for a similar product. Dunno if they are available. I have tried the same thing. You did a much better job though.

462ron - 462ron - 12-29-2025

I don’t know if these are still available. These were from my dad’s stash from his TV repair days in the late 50s early 60s!

Ron    

RE: Transformer Rewire - DaleHCook - 12-29-2025

Although GC (originally General Cement) had a large line of hardware for the radio-TV service trade I do not see those splicers in their catalogs.

RE: Transformer Rewire - Joe Rossi - 12-29-2025

Dan, That is a neat way to protect the transformer wires from further damage.  Thanks for showing us that.

Ron, Those Colman splices look just like Ball-Point pen springs!  Hmm...I'll have to keep my eyes open for some.

RE: Transformer Rewire - radiorich - 12-29-2025

Hello Guys,
Well , I make my own using a pin vice and number drill bits
Spraque made those and marketed them ,
I still have some the original ones .

Sincerely Richard

RE: Transformer Rewire - DaleHCook - 12-29-2025

Richard -

Good idea. I have solid hook-up wire in various gauges, plus full sets of standard and numbered bits.

RE: Transformer Rewire - dconant - 12-29-2025

Pin vise and drill bits nice idea. The pin vise will help while doing the winding. Currently just use my hands. With the new wires I don't even need to label them as I just know where they go based on the color. Thanks for the compliment MrFixr55.

RE: Transformer Rewire - radiorich - 12-30-2025

Hello Guys,

I use 22gauge buss wire but I and thinking of going thinner .
Dconnant , yes I find the pin vise handy

Sincerely Richard

RE: Transformer Rewire - radiorich - 12-30-2025

Hello Guys,
Here is you tube video thanks to Gary Maker for sending this to me

Sincerely Richard

https://www.youtube.com/watch?v=3zo7iXWZhNY

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