Thermal Dynamics PakMaster 100XL problem - output inductor

[86turbodsl]

So my TD Pakmaster 100XL i've owned for about 15 years took a dump today. It wouldn't start the HF arc like normal, tried several times
to get it going and finally gave up and took side covers off, where i immediately found the issue.

The output inductor was sparking through a cracked insulator to a bolt head. The bolt head was eroded away and the insulator fell apart when i touched it.
The part that fell apart was sort of powdered metal, makes me think of ferrite from a magnet, but it wasn't magnetic that i could tell. if it was ferrite,
it's a wierd U-shaped piece and i won't be able to make one nor probably find one on something this old. Does anyone think i could just machine one from plastic/delrin?

Also, the corner of the conductor (very heavy wire) has some burns. It doesn't look like it's down into any of the other windings, so i am assuming i can polish/sand and coat with
some varnish.

Does anyone have any thoughts on this?

See pics.

[Rondo]

So my TD Pakmaster 100XL i've owned for about 15 years took a dump today. It wouldn't start the HF arc like normal, tried several times
to get it going and finally gave up and took side covers off, where i immediately found the issue.

The output inductor was sparking through a cracked insulator to a bolt head. The bolt head was eroded away and the insulator fell apart when i touched it.
The part that fell apart was sort of powdered metal, makes me think of ferrite from a magnet, but it wasn't magnetic that i could tell. if it was ferrite,
it's a wierd U-shaped piece and i won't be able to make one nor probably find one on something this old. Does anyone think i could just machine one from plastic/delrin?

Also, the corner of the conductor (very heavy wire) has some burns. It doesn't look like it's down into any of the other windings, so i am assuming i can polish/sand and coat with
some varnish.

Does anyone have any thoughts on this?

See pics.

I know a lot of repair guys who save everything. I'll start asking around on Monday. Great pics.

[86turbodsl]

I checked the coil and no shorts. I will shoot it with some varnish and see about some plastic for isolator.

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[86turbodsl]

I have varnish and plastic to make a part showing up today. I confirmed that the part that fell apart is some sort of ferrite. Non magnetic itself, but sticks to a magnet. Without having that, i'm betting the arc is a little less stable, but probably not enough flux loss to worry about i think. We shall see tonight.

[86turbodsl]

I shot the coil with 2 coats of electrical varnish today and made a new insulator out of nylon and can confirm the plasma is back to 100pct functional. Seems to be no different in operation.

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