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| We will be putting on four layers of wire. Begin right next to the shaft. Leaving some wire for circuit connections, wind neatly toward the nail
head. Keep each turn of the wire close to the
preceding turn. Upon reaching the nail head,
double back toward the shaft. Then make another
trip to the same nail head, and return again to the shaft.
At this point we cross over to the other side of the armature without changing our coiling direction, and repeat the entire procedure. Two wire ends should now be extending from the center of the armature. Cut them down to about 2”, and scrape the tips bare for connecting to the commutator terminals. (Note: Magnet wire has a decep- tively clear varnish-like insulation on it, which must always be scraped off when making a connection.)
THE COMMUTATOR. For the terminals, cut two 1” by l/2” metal strips. Shape them around any kind of l/2” diameter cylinder so that the length of the terminals runs with the length of the cylinder. Then if you can, solder the armature tips to the ends of the terminals. Otherwise, pierce each terminal with a small nail, loop an armature tip through the hole, and twist tightly.
Now we must build up the shaft diameter to hold the commutator terminals.. Do this by wrap- ping 1” tape on the longer end of the shaft about 3/4” from the armature. Keep wrapping until a 1/2” diameter cylinder is formed.
After looping the excess wire around the armature, place the commutator terminals on the rolled tape as shown on page 30. The space be- tween the long edges of the terminals should be equal on both sides of the commutator.