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VTC Heater Creation

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VTC Heater Insulation

  1. Cut a 49.625 inch length of PTFE tubing 0.6 x 1 mm.
  2. Use awl to ensure ends are open and round.
  3. Mark 3 inches away from end 1 and 3.625 inches away from end 2.
  4. Use the VTT heater insulation clamp to secure the tubing. Slide the silicone sleeve over the tube end, place plastic bracket on top, and clamp on to table. Pull tubing taught until it is straight with no bends.
  5. Cut a 63 inch length of Nichrome 60 36 GA resistance wire.
    A spool of TETEMCo RW0304 36 GA Nichrome 60 Wire behind two weights allowing the spool to turn as the wire is pulled.
    TETEMCo RW0304 36 GA Nichrome 60 Wire
  6. At each end, bend the wire back on itself 5 inches from the end.
    A wire with a clear coating bent back on itself approximately five inches laying on a worktable.
    Wiring bent back on itself approx 5 inches.
  7. Flatten the bend with tweezers.
  8. Clamp the tail end to the main length with a hemostat.
  9. Grasp the bend in a pin vise.
  10. Keep constant tension and spin the pin vise to form a double-helix.
    • The twisted pair must function as a continuous single conductor.
    • Each twist should be 1-2 millimeter
    • There should be no gaps between the two wires.
  11. Thread finished wire into tubing. Use forceps to feed the wire throught, only push about 1/2 to 1 inch in at a time to avoid kinks.
    A close up view of a wire inside of the tubing between a wood block and a work held by a vise grip.
    The wire in a tubing under a block held by a vise grip on a table
    A vise grip with a block of wood holding a long wire on to a worktable is stretched out and inserted into a small tubing inside of another vise grip.
    Full view of the entire length of the wire with loop under vise grip and inserted into tubing.
    Tubing held in a vise grip with finished wire threaded through leaving approximately 1 inch on the other end threaded through.
    Finished wire threaded in tubing.
    Un-twisted length should line up between marks on tubing.
  12. Place 3 inch tube end along line of 3 inch end of mandrel.
  13. Tape 0.125 inch away from 3 inch line using high temperature tape. Follow the guide straight up the mandrel and secure the at the top as well.
  14. At the groove, begin coiling counter-clockwise until mark on tube end 2. (approximately 33.5 turns)
    Coiling wire along line of 3" end of mandrel tape 0.125" away from 3" line and at end of mandrel leaving no gaps between mandrel grooves all the way to the mark on end.
    Begin coiling counter clockwise at the end of the mandrel.
  15. Tape coil to mandrel at mark 2 curve up towards top of mandrel. The tube ends should run along the guide lines on opposite sides of the mandrel. Use tape as necessary to maintain shape and prevent uncoiling.
  16. Apply gentle heat to the coil, especially where the tube bends upwards. Allow it to cool fully and then remove tape.

VTC Heater

  1. Slide the coil onto the VTC conduit. It is easiest to do this one turn at a time. Keep the coil tight and line the two ends of the coil up with the hole in the VTC conduit.
    • Both ends of the coil should now be next to each other.
    • The coil should be centered on the conduit, about 0.125 inch above the hole
    • There should be 20 turns of the coil around the conduit.
  2. Tape at top and bottom of conduit to hold everything in place.
  3. Cut a 1-inch long piece of 750 clear heatshrink, use VTT heatshrink sizer 0.75 to pre-size and remove creases.
    • Air can be used to easily slip heatshrink off of sizer.
  4. Slide heatshrink over conduit and tubing and begin to heat. Before heatshrink is fully tight, pull out the tape at the top and bottom.
  5. Use a razor blade to carefully cut longer end of tubing to match the shorter. Cut around circumference of tube and break off, absolutely do not cut or nick the wire inside. If the wire is cut, it will not function as a conductor.
  6. Attach molex pin male to each end
    • Bend the exposed wires over the tubing
    • Place in pin so that the wire is in contact with the inside of the pin and the tubing is fully secured in the pin crimps. Once crimped, cut the excess wire flush with the pin.
      • Use the red-handled general-purpose molex crimper, using the 2.3mm jaw size.
a wire wrapped counter clockwise around a conduit with out a top end.
Wire wrapped around a conduit, part 1
a wire wrapped around a conduit counterclockwise about 33 times with a top being inserted into the conduit.
Wire wrapped around a conduit, part 2
Wires that were wrapped around the conduit are slid up the conduit towards the top.
Wires slid up the conduit towards the top.
a conduit top coiled tightly approx 33 times and then taped at the very top to keep it from unraveling.
Coiled wire taped to conduit top.
Thermal conduit with TC-T FEP under heatshrink.
Thermal conduit with TC-T FEP under heatshrink.
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