Thermal Dynamics PakMaster 100XL problem - output inductor

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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 timesto 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 withsome varnish.Does anyone have any thoughts on this?  See pics.Miller Syncrowave 300(s)Miller 330 A/BPMiller CP-200 Haas / Kamp'd / CP-300 in processMiller Radiator 1Miller 30A /S-52E feedersHobart GR-303
Reply:Originally Posted by 86turbodslSo 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 timesto 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 withsome varnish.Does anyone have any thoughts on this?  See pics.
Reply:I checked the coil and no shorts.  I will shoot it with some varnish and see about some plastic for isolator.  Sent from my LG-TP450 using TapatalkMiller Syncrowave 300(s)Miller 330 A/BPMiller CP-200 Haas / Kamp'd / CP-300 in processMiller Radiator 1Miller 30A /S-52E feedersHobart GR-303
Reply: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.Miller Syncrowave 300(s)Miller 330 A/BPMiller CP-200 Haas / Kamp'd / CP-300 in processMiller Radiator 1Miller 30A /S-52E feedersHobart GR-303
Reply: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.Sent from my LG-TP450 using TapatalkMiller Syncrowave 300(s)Miller 330 A/BPMiller CP-200 Haas / Kamp'd / CP-300 in processMiller Radiator 1Miller 30A /S-52E feedersHobart GR-303