In the previous article
Antique Ford V8 Ignition Coils with Non-Metallic Cases
John explains how moisture becomes a problem in antique flathead Ford V-8 engine coils with non-metallic cases and the process he has developed to remove the moisture. This process significantly improves coil output voltage resulting in the automobile's ability to better climb hills, go faster, and crank more easily after a short trip.
The original process described in the previous article was first developed in 2002. Since that time it has been significantly automated and improved for even better coil performance.
The moisture removal process was improved greatly in December 2005 by the use of an efficient two-stage vacuum pump capable of removing up to 99.9% of the moisture and other gasses contained in the vessel, and by fully automating the process.
The Updated Process
The coils are processed in a pot heated with heat lamps to about 130 to 135 degrees F. The vessel is alternatively evacuated to extreme negative pressure, and then filled with dry nitrogen. Each of the two-hour cycles consists of 75 minutes at high vacuum, and 45 minutes for nitrogen diffusion at atmospheric pressure.
Under extremely high vacuum, the boiling point of water is depressed to 32 degrees or less while the pot is at 130-135 degrees. Coils held at about 100 degrees above the boiling point of water readily give up the moisture. The pressure variations cause a breathing action that aids moisture removal from the innermost windings and insulation.
Moisture Removal Results
The combined performance of the latest three batches of coils, 59 total, utilizing the high-vacuum pump and an average of 118 - two-hour cycles produced the following:
The average starting voltage was 20,983.
The average finishing voltage was 29,280.
That is an average gain of 8,297 volts per coil or a 39.54% gain.
Recent Process Milestones
The first coil to improve from 0 to 32,000 volts in one pass.
The first coils ever (33 of the 59) to test 32,000 volts on the hot test with 55.93% pegging the meter.
The first measurable quantity of coil water collected at the approximate rate of 6 drops per coil and 10 drops per operating day.
Our Best Run to Date
Voltage Recovery/Moisture Removal 20 Coils
Final Previous %
Coil "Stressed" "Stressed" Voltage Voltage
Number Voltage Voltage Gained Gained
673 32,000 2,000 30,000 1500.0
670 32,000 6,000 26,000 433.3
677 27,500 6,000 21,500 358.3
678 32,000 8,500 23,500 276.5
680 28,000 7,500 20,500 273.3
F676 30,000 11,000 19,000 172.7
652 31,000 12,500 18,500 148.0
F674 32,000 14,000 18,000 128.6
681 32,000 14,000 18,000 128.6
666 27,000 12,000 15,000 125.0
667 31,000 15,000 16,000 106.7
F683 30,000 16,000 14,000 87.5
687 30,000 17,500 12,500 73.5
F675 32,000 20,000 12,000 60.0
669 31,000 20,000 11,000 55.0
F685 27,000 18,000 9,000 50.0
F690 32,000 22,000 10,000 45.5
682 20,000 14,000 6,000 42.9
F688 17,000 12,000 5,000 41.7
691 32,000 23,000 9,000 39.1
Average 29,275 13,550 15,725 116.1%
Pure Speculation
The coils finishing the treatment with 32,000 volt output may even contain less water than they were born with.
John Shelor
(540) 639-16333
The original process described in the previous article was first developed in 2002. Since that time it has been significantly automated and improved for even better coil performance.
The moisture removal process was improved greatly in December 2005 by the use of an efficient two-stage vacuum pump capable of removing up to 99.9% of the moisture and other gasses contained in the vessel, and by fully automating the process.
The Updated Process
The coils are processed in a pot heated with heat lamps to about 130 to 135 degrees F. The vessel is alternatively evacuated to extreme negative pressure, and then filled with dry nitrogen. Each of the two-hour cycles consists of 75 minutes at high vacuum, and 45 minutes for nitrogen diffusion at atmospheric pressure.
Under extremely high vacuum, the boiling point of water is depressed to 32 degrees or less while the pot is at 130-135 degrees. Coils held at about 100 degrees above the boiling point of water readily give up the moisture. The pressure variations cause a breathing action that aids moisture removal from the innermost windings and insulation.
Moisture Removal Results
The combined performance of the latest three batches of coils, 59 total, utilizing the high-vacuum pump and an average of 118 - two-hour cycles produced the following:
The average starting voltage was 20,983.
The average finishing voltage was 29,280.
That is an average gain of 8,297 volts per coil or a 39.54% gain.
Recent Process Milestones
The first coil to improve from 0 to 32,000 volts in one pass.
The first coils ever (33 of the 59) to test 32,000 volts on the hot test with 55.93% pegging the meter.
The first measurable quantity of coil water collected at the approximate rate of 6 drops per coil and 10 drops per operating day.
Our Best Run to Date
Voltage Recovery/Moisture Removal 20 Coils
Final Previous %
Coil "Stressed" "Stressed" Voltage Voltage
Number Voltage Voltage Gained Gained
673 32,000 2,000 30,000 1500.0
670 32,000 6,000 26,000 433.3
677 27,500 6,000 21,500 358.3
678 32,000 8,500 23,500 276.5
680 28,000 7,500 20,500 273.3
F676 30,000 11,000 19,000 172.7
652 31,000 12,500 18,500 148.0
F674 32,000 14,000 18,000 128.6
681 32,000 14,000 18,000 128.6
666 27,000 12,000 15,000 125.0
667 31,000 15,000 16,000 106.7
F683 30,000 16,000 14,000 87.5
687 30,000 17,500 12,500 73.5
F675 32,000 20,000 12,000 60.0
669 31,000 20,000 11,000 55.0
F685 27,000 18,000 9,000 50.0
F690 32,000 22,000 10,000 45.5
682 20,000 14,000 6,000 42.9
F688 17,000 12,000 5,000 41.7
691 32,000 23,000 9,000 39.1
Average 29,275 13,550 15,725 116.1%
Pure Speculation
The coils finishing the treatment with 32,000 volt output may even contain less water than they were born with.
John Shelor
(540) 639-16333