Please see the [Transcriber’s Notes] at the end of this text.

The cover image has been created for this text and is placed in the public domain.

Harper’s Practical Books for Boys

A SERIES OF NEW HANDY-BOOKS
FOR AMERICAN BOYS

Each Crown 8vo, with many Illustrations.

I

HARPER’S OUTDOOR BOOK FOR BOYS

By Joseph H. Adams. With Additional Contributions by Kirk Munroe, Tappan Adney, Capt. Howard Patterson, L. M. Yale, and others. Cloth, $1.75.

II

HARPER’S ELECTRICITY BOOK FOR BOYS

Written and Illustrated by Joseph H. Adams. With a Dictionary of Electrical Terms. Cloth, $1.75.

IN PRESS

III

HARPER’S HOW TO UNDERSTAND ELECTRICAL WORK

A Simple Explanation of Electric Light, Heat, Power, and Traction in Daily Life. By Joseph B. Baker, Technical Editor, U. S. Geological Survey, formerly of the General Electric Company.

IV

HARPER’S INDOOR BOOK FOR BOYS

By Joseph H. Adams and others. Cloth, $1.75.

V

HARPER’S MACHINERY BOOK FOR BOYS

The Boy’s Own Book of Engines and Machinery. Cloth, $1.75.

HARPER & BROTHERS, PUBLISHERS, NEW YORK

Copyright, 1907, by Joseph H. Adams, N. Y.

THOMAS A. EDISON DICTATING TO HIS GRAPHOPHONE

HARPER’S
ELECTRICITY BOOK
FOR BOYS

WRITTEN AND ILLUSTRATED BY
JOSEPH H. ADAMS

AUTHOR OF
“HARPER’S OUTDOOR BOOK FOR BOYS”

WITH AN EXPLANATION OF ELECTRIC LIGHT, HEAT
POWER, AND TRACTION BY JOSEPH B. BAKER
TECHNICAL EDITOR, U. S. GEOLOGICAL SURVEY

AND
A DICTIONARY OF ELECTRICAL TERMS

HARPER & BROTHERS PUBLISHERS
NEW YORK AND LONDON
MCMVII

Copyright, 1907, by Harper & Brothers.
All rights reserved.
Published November, 1907.

CONTENTS

INTRODUCTION

If a handy-book of electricity like this had fallen into the hands of Thomas A. Edison when he was a newsboy on the Grand Trunk Railway, or when he was a telegraph operator, he would have devoured it with the utmost eagerness. To be sure, at that time, in the early sixties, all that we knew of electricity and its applications could have been told in a very brief compass. It was an almost unknown field, and the crude form of the telegraph then in use represented its most important application. There were no electric lights; there was no telephone or phonograph; there were no electric motors. Telegraphing, itself, was a slow and difficult process. All the conditions were as far removed as possible from the broad field of applied electricity indicated in this book.

But this does not mean that we have now accomplished all that there is to be done. On the contrary, the next half-century will be full of wonderful advances. This makes it more than ever essential that we should become acquainted with the principles and present conditions of a science which is being applied more and more closely to the work of every-day life. It is necessary to know this from the inside, not simply from general descriptions. Theory is all very well, but there is nothing like mastering principles, and then applying them and working out results for one’s self. Any active and intelligent boy with an inquiring mind will find a new world opened to him in the satisfaction of making electrical devices for himself according to the suggestions given in this book. This will show him the reasons for things in concrete form, will familiarize him with principles, and will develop his mechanical ingenuity. He may be laying the foundation for inventions of his own or for professional success in some of the many fields which electricity now offers. Work of this kind brings out what is in one, and there is no satisfaction greater than that of winning success by one’s own efforts.

The boy who makes a push-button for his own home, or builds his own telephone line or wireless telegraph plant, or by his own ingenuity makes electricity run his mother’s sewing-machine and do other home work, has learned applications of theory which he will never forget. The new world which he will enter is a modern fairyland of science, for in the use of electricity he has added to himself the control of a powerful genie, a willing and most useful servant, who will do his errands or provide new playthings, who will give him manual training and a vast increase in general knowledge. The contents of this book, ranging from the preparation of simple cells to the making of dynamos and motors, and the delightful possibilities of electro-plating, shows the richness of the field which is made accessible by Mr. Adams’ practical explanations, his carefully tested working plans, and his numerous and admirable drawings—all of which have been made for this book.

It is in keeping with the practical character of the Electricity Book that pains are taken throughout to show the simplest and most inexpensive way of choosing materials and securing results. The actual working out of these directions can be done at very small expense. Furthermore, there need be no concern whatever as to possible danger if the book is read with reasonable intelligence. Mr. Adams has taken pains to place danger-signals wherever special precautions are advisable, and, as a father of boys who are constantly working with electricity in his laboratory, he may be relied upon as a safe and sure counsellor and guide.

While this book shows boys what they can do themselves, its scope has been enlarged by Mr. Baker’s [chapter] explaining briefly the working of electricity all about us, in light and heat, in the trolley-car, and other daily applications. In addition, Mr. Adams has prepared a Dictionary of Electrical Terms, and these brief definitions will be found peculiarly helpful in the first reading of the book. It is believed that there is no book in this particular field comparable to Harper’s Electricity Book in its comprehensiveness, practical character, and the number and usefulness of its illustrations. It follows the successful Out-door Book for Boys in Harper’s series of Practical Books for Boys, and it will be followed by How to Understand Electrical Work, a book, not of instructions in making electrical apparatus, but of explanations of the commercial uses of electricity all about us.

Part I

ELECTRICITY BOOK FOR BOYS

Chapter I
SOME GENERAL EXPLANATIONS

We are living in the age of electricity, just as our fathers lived in the age of steam. Electricity is the world-power, the most powerful and terrible of nature’s hidden forces. Yet, when man has learned how to harness its fiery energies, electricity becomes the most docile and useful of his servants. Unquestionably, electricity is to-day the most fascinating and the most profitable field for the investigator and the inventor. The best brains of the country are at work upon its problems. New discoveries are constantly being recorded, and no labor is thought too great if it but add its mite to the sum total of our knowledge. And yet, ridiculous as the statement may seem, we do not know what electricity is. We only know certain of its manifestations—what it can do. All we can say is that it does our bidding; it propels our trains, lights our houses and streets, warms us, cooks for us, and performs a thousand and one other tasks at the turn of a button or at the thrust of a switch. But what it is, we do not know. Electricity has no weight, no bulk, no color. No one has seen it; it cannot be classified, nor analyzed, nor resolved into its ultimate elements by any known process of science. We must content ourselves with describing it as one manifestation of the energy which fills the universe and appears in a variety of forms—such as heat, light, magnetism, chemical affinity, and mechanical motion. In all probability it is one of those phenomena of nature that are destined to remain forever secret. Thus it stands in line with gravitation, magnetism, the active principle of radium, and the perpetual motion of the solar system.

Electricity was known to the early Greeks; indeed, it derives its name from the Greek word for amber (electron). For many centuries amber was credited with certain special or magical powers. When it was rubbed with a flannel cloth, “the hidden spirit” came out and laid hold of small detached objects, such as bits of paper, thread, chips, or pith-balls. No one could explain this phenomenon. It was looked upon with superstitious awe and the amber itself was regarded as possessing the special attributes of divinity. But as time went on, it was discovered that in various other substances this mysterious attractive power could be excited, at will, through the agency of friction. Rubbing a piece of glass rod with silk or leather generated an “electricity” identical with that of the amber; or the same result could be obtained by exciting hard rubber with catskin. The conclusion followed that electricity was not a property of the special materials employed to generate it, but that it came from without, from that great reservoir of energy, the atmosphere. Then came Franklin with his experiment of the kite, and the invention of the Leyden-jar and the chemical production of the electric fluid by means of batteries. It was shown that the properties of the new and strange force were the same, whether it was produced by the static (frictional) process or by the galvanic (chemical) method. Electrical science as a science, had begun.

And yet, for many years, electricity was hardly more than a scientific toy. It was not supposed to possess any practical usefulness. The entertaining experiments with the static machine and the Leyden-jar ([chapter xiii.]) were confined to the laboratory and the lecture hall. Electricity was an amusing display of unknown energy, but no one ever dreamed that it could ever be made to serve the practical ends of life. It was not until about 1850 that electrical science became anything more than a name. The galvanic and voltaic batteries ([chapter ii.]) opened the way for “current” electricity, which flowed continuously, instead of jumping and disappearing like the spark from a Leyden-jar. When the continuous current became an established fact, the telegraph and telephone headed the line of a long series of developments. Finally, the generation of electricity in greater volume, and cheaply, made possible the application of its power for heating, light, traction, and the other forms of activity in which it now does so large a share of the world’s work.

How electricity works is a question often asked, but not easily answered. There are certain so-called laws, but we shall best arrive at a conclusion by simply stating a few of the facts that have been established through the observation and investigation of scientists and electrical engineers.[1]

[1] Explanations of any technical names or phrases used in the text will be found in the simple [dictionary of electrical terms] which appears as an appendix.

For example, electricity is always alert, ready to move, and continually on the lookout for a chance to obtain its freedom. It will never go the longest way round if there is a short cut; and it will heat, light, or fuse anything in its path that is too weak to carry or resist it. For this reason, it must be generated in small volume—that is, just sufficient to do the work required of it. If produced in larger volume, it must be held in check by resistance, and only so much allowed to escape as may be needed for the specified work.

Again, when electricity is generated this must be done in one of two ways—by friction or chemically. But in both processes there must be air surrounding the generators, and the fluid must be of a nature through which oxygen and hydrogen can circulate freely. Water fluids are suitable for this purpose, but oils cannot be used, as they contain hydro-carbon in large quantities and are non-conductors.

Batteries are chemical generators, dynamos are magneto-electric, and static machines are frictional. Now the theory is that electricity is drawn from the ether and, in its normal state, is quiet. If it be disturbed and collected by mechanical or chemical means, it is always on the alert to escape and again take its place in the atmosphere. As its volume is increased, so its energy to get away is multiplied, and this energy may be transformed, at will, into power, heat, or light. To express the idea in the simplest language, it wants to go home, and in its effort to do so it expresses itself in the form of stored-up power, precisely like water behind a dam. It is for man’s cunning brain to devise all sorts of tasks that this power must perform before it can gain its release. It can’t go home until its work is done.

Nearly every boy has experimented, at one time or another, with electricity and electrical apparatus, and whether it was with some of the simple frictional or galvanic toys, or with the more complicated induction-coils and motors, he has undoubtedly found it a most interesting amusement and an ever new and widening field for study. Then again, many boys would like to know something about simple electrical apparatus and how to make and use it. But his school-books relating to the general subject of electricity are hardly definite enough to serve as a practical manual. And yet there are many things in the way of electrical machinery and equipment that a boy can easily construct and use. In this book it is my purpose to show him just what can be done with the aid of the tools that are usually in his possession. While some things may have to be purchased from an electrical supply-house or other sources, there is still much material to be found about the house that may be put to good use by the amateur electrician.

It is not possible or desirable to describe every variety of electrical equipment. We must confine ourselves to apparatus which can be readily understood and operated. The “practical” idea is the one to be borne in mind. This book shows a boy how to use his brains and the simple tools and material that may be at his command. Care and thought in the construction of the apparatus are the important qualifications for success. The instructions are given in the clearest possible language; the diagrams and drawings are intelligible to any one who will take the trouble to study them. If your finished apparatus does not work properly, read the description again and see if you have not made some error. A misplaced or broken wire, a wrong connection, or a short circuit will mean all the difference between success and failure.

Save in one short chapter, static or frictional electricity (see [Appendix]) is not considered; for outside of laboratory experimenting and electro-medical apparatus, frictional electricity is but a toy—interesting and useful when generated in small volume, but very dangerous and difficult of control when in great volume. For example, the bolt of lightning is but the many times multiplied spark stored in the Leyden-jar by the static machine. For all practical purposes, galvanic electricity, in its various phases of direct and alternating current, meets the requirements of man. With the improved apparatus and the rapid advancement along the line of invention, electricity is as easily controlled to-day as steam—in fact, its economical use is even more fully under control and its adaptability more practical.

In the following pages there are probably illustrations and descriptions of many things that will seem strange to the boy who has not heard of them; but if a book were written each year on the subject of electricity, every new one would include principles and facts not known before. The field of electrical research is so broad and so many are working in it that new discoveries are being made continually.

To those familiar with the application of electricity, it is clearly evident that, as yet, we are only beginning to deal with this unknown force. For generations to come, developments will take place and invention follow invention until electricity assumes its rightful place as the motive force of the world. To the boy interested in this subject a wide field is open, and the youth of to-day, who are taking up this study, are destined to become the successful electrical engineers and inventors of the future. There is no better education for any boy, in the application and principles of electricity, than to begin at the very bottom of the ladder and climb up, constructing and studying as he progresses. When he attempts to design more technical and difficult apparatus the lessons learned in a practical way will be of inestimable value, greater by far than any theoretical principles deduced from books; he knows his subject from the ground up; he understands his machine because he has constructed it with his own hands.

As I have said already, the necessary tools are few in number and not expensive. They may include a hammer, a plane, awls, pliers, wire-cutters, and tin-shears. The raw material is also cheap—lead, tin, wire, wood, and simple chemicals. The laboratory may be a corner in the attic, or even in a boy’s bedroom, so far as the finer work is concerned, while the hammering and sawing may be done in the cellar. The other best plan, of course, is to get the use of a spare room which may be fitted with shelves, drawers, and appliances for serious work. To enthusiastic beginners, as well as to those who have had some experience in electricity, a needed warning may be given in three words: “Take no chances.” Electricity, the subtle, stealthy, and ever-alert force, will often deal a blow when least expected. For that reason, a boy should never meddle with a high-tension current or with the mains from dynamos. The current in the house, used for lighting, cooking, or heating purposes, is always an attractive point for the young electrician, but the wires should never be touched in any way. Too many accidents have happened, and the conductors, lamp-sockets, and plugs should be carefully avoided.

The boy should keep strictly to his batteries, or small dynamos run by water-power from a faucet; in no case should the wire from power-houses be tampered with. One little knows what a current it may be carrying and what a death-dealing force it possesses. Always bear in mind that a naked wire falling from a trolley equipment carries enough force to kill anything it strikes.

Special attention is called to the dictionary of electrical terms given in the [Appendix]. The young student should never pass over a word or a term that he does not thoroughly understand. Always look it up at once and every time it occurs, until you are sure that its meaning is fixed in your mind. This is an education in itself, at least so far as the theoretical knowledge of our subject is concerned.

As a final word, I should like every boy interested in electricity to hear what Thomas A. Edison once said to me when I was a boy working in his laboratories. I often recall it when things do not go just right at first.

I asked the great inventor one day if invention was not made up largely of inspiration. He looked at me quizzically for a moment, and then replied: “My boy, I have little use for a man who works on inspiration. Invention is two parts inspiration and ninety-eight per cent. perspiration.”

You will never get what you are after unless you work hard for it. You must stick to it until you produce results. If the history of the world’s most valuable inventions could be fully known, the fact would be clearly established that the vital spark of inspiration is but the starting-point. Then follow the days, weeks, and sometimes years of industrious toil, failures, and disappointments, until finally the desired end is attained. One must work for success; there is no other means of winning it.

As the [table of contents] shows, [Part I.] of this book explains principles and the simpler forms of electrical appliances. From this we advance to [Part II.], which deals with more complex forms of electrical work, most of which, however, are within the reach of intelligent boys who have followed the chapters carefully from the first. In a [final chapter] we have simple explanations of the great commercial uses of electricity, which we see all about us, although very few of us have a clear idea as to their operation.

Chapter II
CELLS AND BATTERIES

Simple Cells

In order to generate electricity it is necessary to employ cells, batteries, or dynamos. Since the construction and operation of a dynamo is somewhat intricate, it will be better to start with the simpler methods of electric generation, and so work up to the more complicated forms. For small apparatus, such as electric bells and light magnets and motors, the zinc-carbon-sal-ammoniac cell will answer very well; but for larger machinery, where more current is required, the bluestone and the bi-chromate batteries will be found necessary.

SIMPLE BATTERY ELEMENTS

A simple and inexpensive cell may be made from electric-light carbons, with the copper coating removed, and pencils of zinc, such as are used for electric-bell batteries and which can be purchased for five cents each. Copper wire is to be bound around the top of each pencil of carbon and zinc, and firmly fastened with the pliers, so that it will not pull off or become detached. It will be well to cut a groove with a file around the top of both the carbon and zinc, into which the wire will fit. The elements should then be clamped between two pieces of wood and held with screws, as shown in [Fig. 1]. A more efficient carbon pole is made by strapping six or more short carbon pencils around one long one, as shown in [Fig. 3]. The short pieces of electric-light carbons are bound to the longest carbon with heavy elastic bands, or cotton string dipped in paraffine or wax, to make the cotton impervious to water and the sal-ammoniac solution.

Another arrangement of elements is shown in [Fig. 2], where a zinc rod is suspended between two carbons, the carbons being connected by a wire that must not touch the zinc.

A fruit-jar, or a wide-necked pickle-bottle, may be employed for a cell, but before the solution is poured in, the upper edge of the glass should be coated with paraffine. This should be melted and applied with a brush, or the edge of the glass dipped in the paraffine.

The solution is made by dissolving four ounces of sal-ammoniac in a pint of water, and the jar should be filled three-fourths full. In this solution the carbons and zinc may be suspended, as shown in the illustration ([Fig. 4]) of the sal-ammoniac cell. The wood clamps keep the carbon and zinc together, and the extending ends rest on the top of the jar and hold the poles in suspension. Plates of zinc and carbon may be clamped on either side of a square stick and suspended in the sal-ammoniac solution, as shown in [Fig. 5], taking care, however, that the screws used for clamping do not touch each other.

If one cell is not sufficiently powerful, several of them may be made and coupled up in series—that is, by carrying the wire from the zinc of one to the carbon of the next cell, and so on to the end, taking care that the wire from the carbon in the first cell and that from the zinc of the last cell will be the ones in hand, as shown in [Fig. 6]. This constitutes a battery. Be sure and keep the ends of the wire apart, to prevent galvanic action and to save the power of the batteries.

This battery is an excellent one for bells and small experimental work, and when inactive the zincs are not eaten away (as they would be if suspended in a bi-chromate solution), for corrosion takes place only as the electricity is required, or when the circuit is closed. A series of batteries of this description will last about twelve months, if used for a bell, and at the end of that time will only require a new zinc and fresh solution.

The cell in which the plates shown in [Fig. 5] are used may contain a bi-chromate solution; and for experimental work, where electricity is required for a short time only, this will produce a stronger current. But remember that the solution eats the zinc rapidly, and the plates must be removed as soon as you have finished using them.

The bi-chromate solution is made by slowly pouring four ounces of commercial sulphuric acid into a quart of cold water. This should be done in an earthen jar, since the heat generated by adding acid to water is enough to crack a glass bottle. Never pour the water into the acid. When the solution is about cold, add four ounces of bi-chromate of potash, and shake or mix it occasionally until dissolved; then place it in a bottle and label it:

BI-CHROMATE BATTERY FLUID
POISON

Before the zincs are immersed in the bi-chromate solution they should be well amalgamated to prevent the acid from eating them too rapidly.

The amalgamating is done by immersing the zincs in a diluted solution of sulphuric acid for a few seconds, and then rubbing mercury (quicksilver) on the surfaces. The mercury will adhere to the chemically cleaned surfaces of any metal except iron and steel, and so prevent the corroding action of the acid. Do not get on too much mercury, but only enough to give the zinc a thin coat, so that it will present a silvery or shiny surface.

A two-fluid cell is made with an outer glass or porcelain jar and an inner porous cup through which the current can pass when the cup is wet. [Fig. 7].

A porous cup is an unglazed earthen receptacle, similar to a flower-pot, through which moisture will pass slowly. The porous cup contains an amalgamated plate of zinc immersed in a solution of diluted sulphuric acid—one ounce to one pint of water. The outer cell contains a saturated solution of sulphate of copper in which a cylindrical piece of thin sheet-copper is held by a thin copper strap, bent over the edge of the outer cell. A few lumps or crystals of the copper sulphate, or bluestone, should be dropped to the bottom of the jar to keep the copper solution saturated at all times. When not in use, the zinc should be removed from the inner cell and washed off; and if the battery is not to be employed for several days, it would be well to pour the solutions back into bottles and wash the several parts of the battery, so that it may be fresh and strong when next required. When in action, the solutions in both cups should be at the same level, and be careful never to allow the solutions to get mixed or the copper solution to touch the zinc. Coat the top of the porous cell with paraffine to prevent crystallization, and also to keep it clean. Take great care, in handling the acid solutions, to wear old clothes, and do not let the liquids spatter, for they are strong enough to eat holes in almost anything, and even to char wood. The two-fluid cells are much stronger than the one-solution cells, and connected up in series they will develop considerable power.

For telegraph-sounders, large electric bells, and as accumulators for charging storage-batteries, the gravity-cell will give the most satisfactory results. The one shown in [Fig. 8] consists of a deep glass jar, three strips of thin copper riveted together, and a zinc crow-foot that is caught on the upper edge of the glass jar. These parts will have to be purchased at a supply-house, together with a pound or two of sulphate of copper (bluestone).

To set up the cell, place the copper at the bottom and drop in enough of the crystals to generously cover the bottom, but do not try to imbed the metallic copper in the crystals; then fill the jar half full of clear water. In another jar dissolve two ounces of sulphate of zinc in enough water to complete the filling of the jar to within two inches of the top; then hang the zinc crow-foot on the edge of the jar so that it is immersed in the liquid and is suspended about three inches above the top of the copper strip. The wire that leads up from the copper should be insulated with a water-proof coating and well covered with paraffine. A number of these cells may be connected in series to increase the power of the current, and for a working-battery this will show a high efficiency. Note that at first the solutions will mingle. To separate them, join the two wires and start the action; then, in a few hours, a dividing line will be seen between the white, or clear, and the blue solutions, and the action of the cell will be stronger. After long-continued use it may be necessary to draw off some of the clear zinc sulphate, or top solution, and replace it with pure water. The action of the acids reduces the metallic zinc to zinc sulphate and deposits metallic copper on the thin copper strips, and in this process an electrical current is generated.

A Plunge-battery

When two or more cells (in which sulphuric acid, bi-chromate of potash, or other strong electropoions are employed) are coupled in series, it would be well to arrange the copper and zinc, or the zinc and carbon, poles on a board, so that all of them may be lowered together into the solutions contained in the several jars. A simple arrangement of this kind is shown in [Fig. 9], where a rack is built for the jars and at the top of the end boards a projecting piece of wood, supported by a bracket, is made fast. A narrow piece of board nearly the length of the jar-rack is fitted with the battery-poles, as shown at [Fig. 9] A. The carbon and zinc, or copper and zinc, poles are attached to small blocks of wood (as described for [Fig. 5]), and this block in turn is fastened to the under side of the board with brass screws. The poles of the cells are to be connected (as explained in [Fig. 6]), and when the battery is in use the poles are immersed in the solution contained in the jars. When the battery is at rest the narrow board should be lifted up and placed on the projecting arms of the rack, so that the liquid on the poles may drain into the jars directly underneath. One or more of these battery-racks may be constructed, but they cannot be made to hold conveniently more than four or six cells each; if more cells are required, those contained in each rack must be coupled up in series.

A simpler plunge-battery is shown in [Fig. 10]. A cell-rack is made of wood and given two or three coats of shellac. The narrow board (to the under side of which the battery-poles are attached, as explained in [Fig. 9]) is hung on chains or flexible wires, which in turn are made fast to an iron shaft running the entire length of the cell-rack. This shaft is of half-inch round iron, and is held in place, at one end, by a pin and washer; while at the other the end is filed with a square shoulder, and a handle and crank is fitted to it, so that the shaft may be turned. A small hole, made at the side of the crank when it is hanging down, will receive a hard-wood peg, or a steel nail, and this will prevent the crank from slipping when the board holding the poles is raised. If a gear-wheel and tongue can be had to fit on the shaft, it will then be possible to check the shaft securely at any part of a turn of the crank. The battery-poles are to be connected in series along the top of the portable board, as explained for [Fig. 6]. When two or more of these plunge-batteries are used at one time, the wire from the carbon of one is to be connected with the zinc pole of the next, and so on. The wire from the zinc of the first battery, and the wire from the carbon of the last battery, will be the ones available for use.

A Storage-battery

When more current is desired than the simple batteries will give, a storage-battery should be employed as an accumulator. This result can be secured by coupling primary cells in series, so that they will be constantly generating and feeding the battery. Storage-batteries are too heavy to be shifted about, like single cells or small plunge-batteries; they should be placed in a cellar, where the charging or primary cells can be located close by, and, unless positively necessary, the battery of cells and the accumulator should not be moved.

With sufficiently large insulated wires (Nos. 12, 14, or 16 copper), the current may be carried to any part of the house for use in various ways—such as running a light motor or a fan, lighting a lamp-circuit, or fusing metals and chemicals for experimental purposes. While the battery to be described is not a light one in weight, nor as economical as the improved new Edison storage-battery, it is a good and constant one, and, if not overcharged or abused, will last for several years.

The component parts of a storage-battery are lead in metallic and chemical form, the electrolyte, or fluid, in which the plates are immersed, and the water-tight and chemical-proof cell or container. From a plumber, a supply-house, or a lead-works, obtain a quantity of three-eighth by one-quarter-inch strip-lead of the kind called chemical, or desilverized; also a larger quantity of lead-tape, one-sixty-fourth of an inch thick and three-eighths of an inch wide. This last is also known as torpedo-lead, and is kept by electrical supply-houses.

If the three-eighths by quarter-inch strip-lead cannot be had, then purchase eight or ten pounds of heavy sheet-lead, and, with a tin-shears, divide it into strips three-eighths of an inch wide and twenty-nine inches long, taking care to cut it of uniform width and with true edges. From hard-wood three-eighths or half an inch thick, cut a block six by seven inches and make four countersunk holes in it, so that it may be screwed fast to a table or bench, as shown in [Fig. 11] A. Around this the lead strips should be shaped and beaten at the corners to make the angles sharp.

From the three-eighths by quarter-inch, or sheet-lead strips, make seven frames as shown in [Fig. 12]. This is done by binding a strip of the lead around the block, as shown at [Fig. 11] B. Where the ends come together insert a short piece of lead, three-eighths or half-inch, as shown at [Fig. 12] A, and solder it fast. A soldering-iron may be heated with a Bunsen-burner gas-flame or in a charcoal fire. However, if gas is available, it would be better to use the blue flame from a Bunsen burner and direct the hot blast directly on the work with a blow-pipe, and so fuse the lead points together. After a little practice with the blow-pipe it will be used for many pieces of work in preference to the soldering-iron. If the sheet-lead is used for the frames in place of the three-eighths by quarter-inch strips, two or three strips will have to be taken, so as to build up the band of the frame to about a quarter of an inch in thickness. When soldered together, or fused at the edges, these built-up frames will be as rigid as the solid metal.

Now cut a number of strips of the thin lead-tape six inches and a half long, and others that will necessarily be somewhat longer, for each frame is to be filled with straight and crimped pieces, as shown in [Fig. 13]. If there is a fluting-iron in the house, the crimping may be done in the brass gears at one end of the machine. Or two wheels may be cut from hard-wood with a fret-saw, and made fast to a block with screws, as shown in [Fig. 14]. A handle, attached to one wheel, will make it possible to turn the gears; and they should be placed just far enough apart to allow the tape to pass through without tearing or squeezing. Put a washer between the wheel and the block to prevent friction.

When a frame is in the position shown in [Fig. 13], and lying on a piece of slate or flat stone, you will first put in a crimped piece of tape, as shown at [Fig. 13] A, and under this arrange a straight piece ([Fig. 13] B); then, with the blow-pipe and flame, fuse fast to the frame and catch the flutes of the crimped piece to the straight one every inch or two. Add alternate crimped and straight strips until the frame is filled and presents the appearance of [Fig. 13]. When the seven frames are ready, lay three of them aside for the positives and four for the negatives. Note that the positives are red and the negatives a dark yellow when they are filled with the active material.

There are several methods of depositing the active material in the mesh or net-work of the plates, but some of them are too technical, others too complicated, and still others require charging machinery. The following plan will be the simplest and easiest for the amateur:

At a paint-store, or from a wholesale druggist, obtain several pounds of oxide of lead (red-lead) and a similar quantity of litharge (yellow-lead). In an earthen vessel, or large jar, make a solution composed of water, twenty ounces, and commercial sulphuric acid, two ounces. This is the mixture commonly known as “one to ten.” Place some red-lead (dry) in an old saucepan or soup-plate, and add a little of the acid solution: then, with an old table-knife or small trowel, mix the lead into a stiff paste, like soft putty. Do not get it too thin or it will run; nor too thick, as then it will not properly adhere to the lead-mesh of the frames. With the frame lying on its side, plaster in the red composition between the flutes and fill up the frame solid with it. Treat all three of the positive frames in the same manner, taking care that the exposed surfaces of the composition-filling is smooth and flush with the edges of the lead frame and mesh. Do not disturb these plates for a while, but let them remain in position, so as to set and partially dry. Add acid solution to the yellow-lead in a similar manner, and fill the four negative plates. When partially dry, the plates will be ready to combine in a pile.

At a supply-house obtain some sheets of cellulous fibre, three-sixteenths of an inch thick, or some asbestos cloth. If neither can be had, then soak some pieces of ordinary brown card-board in a solution of silicate of soda and let them dry. Lay a negative (yellow) plate on the table with the lug at the left ([Fig. 13] C). On this place a square of the fibre, asbestos, or card-board; and on top of it lay a positive (red) plate with the lug at the right side. Continue in this manner until the seven plates are stacked, the four negative lugs being at the left and the three positives at the right. Tie the plates securely together with cotton string bound about them in both directions; then stand the pile up so that the lugs are at the top, as shown at [Fig. 15], with every alternate lug in an opposite direction. Obtain two lead bars three-eighths of an inch square, or cut strips from the sheet-lead and solder them together, turning the ends as shown at [Fig. 13] D. Drop one of these bars into the lugs of the positive plates, as shown in [Fig. 15] H, and solder it fast at the three unions. Repeat this with the other bar in the lugs of the negative plates, and the pile will then be ready for immersion in the electrolyte. To both ends of each plate-bar solder binding-posts, so that the conductor-wires can be attached at one end and the feed-wires at the other. If a hard rubber or glass cell can be had for the battery so much the better; if not, a stout box may be made from pine, white-wood, or cypress, and thoroughly coated with asphaltum varnish or asphaltick. At an electrical supply-house you can purchase some “P and B” compound, which is acid and water proof. This is excellent for the inside coating as well as for the outside of the box.

The box should be made of wood not less than three-quarters of an inch thick, and the sides, ends, and bottom should be in one piece, free from knots, sappy places, or cracks. Brass screws should be used to hold the boards together, and before the joints are made the butt-ends of wood and the sides, against which they impinge, must be thoroughly coated with the asphaltum or compound. Put together the four sides first and then make the bottom fast, placing the screws two inches apart and countersinking the wood, so that the screw-heads will lie flush, as shown in [Fig. 16]. The box should be large enough to allow about one inch of space all around the pile, and deep enough for the solution to cover the plates and two inches of space above it to the top edge of the cell. The complete storage-battery will then appear as shown in [Fig. 17].

The electrolyte is composed of sulphuric acid and water in the proportion of one ounce of acid to four of water, making a five-part solution. This should be mixed in an earthen or glass jar, and the acid poured slowly into the water, the latter being stirred while the acid is added. When the solution cools (for adding acid to water creates heat), add about two ounces of bicarbonate of soda, and mix the solution thoroughly.

When the pile is in place within the box (having first removed the string which bound the plates together) pour the electrolyte slowly into the cell, taking care that none of it spatters, for it will eat clothing or anything else that it touches. Before placing the pile, or electrolyte, in the box, it should be thoroughly tested for leaks by allowing water to stand in it for several days. Indeed, you should be very generous with the asphaltum, or compound, when coating the angles and points inside the box; for if the acid solution gets at the screws it will corrode them and the box will soon leak and fall apart. As a precaution against the acid working over the top of the box, the upper edge, for an inch or two, should be coated with paraffine over the asphaltum or acid-proof coating.

A cell constructed in this way should accumulate about two volts and one hundred ampere-hours, and will run a one-sixteenth horse-power motor. The expense of making these plates is about twenty-five cents each, and, including the cell and coating materials, each storage-battery will cost approximately two dollars. The lasting qualities of the battery depend on the use or abuse it is put to; but with ordinary care it should last from three to five years.

When the battery ceases to accumulate properly the pile should be removed, and, after washing it thoroughly, the bars should be cut away and new positive plates made and installed. The positive plates are the ones that deteriorate and need replacing; the negatives are almost everlasting, and with proper usage will live for fifteen or twenty years.

Directly the electrolyte is in the cell, connect the poles of your primary cells so as to begin the accumulation of current. Never exhaust the charge of electricity from your storage-cell, and never leave it uncharged when the electrolyte is in, or the plates will be ruined. A battery consisting of from five to twenty bluestone cells will be the best with which to charge this accumulator; and if more than one cell is desired, any number of them can be made and coupled up in series. Take care, when connecting the wires from the primary cells, to see that the positive wire is connected with the positive plates and the negative with the lead bar joining the yellow plates. If by accident you should make a misconnection, bubbles will rise from the electrolyte. This is not right, so reverse the wires and the accumulation of current will then take place without agitation in the cell.

Dry-cells and Batteries

Dry-cells are extensively used nowadays, since their cleanliness, high efficiency, and low internal resistance make them preferable to the Leclanché and other open-circuit batteries for bells, annunciators, and other light work. In the dry-cell, the electrolyte, instead of being a liquid, is a gelatinous or semi-solid mass, which will not run nor slop over. When the capping of pitch or tar is in place, the cell may be placed in any position, with full assurance that the electrolyte will not become displaced nor run out. Dry-cells may be made of almost any size for convenience of handling, but those commonly used vary from one to four inches in diameter, and from four to fifteen inches high. For bells and general electric work, a cell two inches and a half in diameter and seven inches high will be found a convenient size to make and handle.

The component parts of a dry-cell are the cell itself (which is made of zinc and acts as the positive pole), the carbon, the electrolyte or active excitant element, and the pitch or tar cap to hold the electrolyte and carbon in place.

From a tinsmith obtain some pieces of sheet zinc, and roll them into cylindrical form as shown in [Fig. 18] A. The sheets should measure seven by eight inches, and when formed the edges are to be lapped and soldered.

From a smaller piece of zinc cut round bottoms, fit them in the cylinders and solder securely in place, taking care to close up all seams or joints to prevent the escape of the electrolyte.

From a supply-house obtain battery-carbons, one inch and a half wide by half or three-eighths of an inch thick and eight inches long. These should be provided with a thumb-screw or small bolt and nut at the top so as to make wire connections with the carbon. A strip of zinc should be soldered to the outside upper edge of the zinc cup to which wire attachments may be made with thumb-screws or small bolts and nuts. When the parts are ready to assemble, make a wooden mould or form a trifle larger than the carbon. This is intended to act as a temporary plunger, and is inserted, at first, in place of the carbon plate. This wooden plunger should be smooth, and given a coat of shellac to prevent it from absorbing any moisture.

Insert the plunger in the zinc cup and support it so that it will be at least half an inch above the bottom and centred at the middle of the cup. The electrolyte is then placed in the cup, and, when it has set a little, the wooden plunger is removed and the carbon inserted in its place.

The electrolyte is composed as follows:

Mix these together and place the compound within the zinc cups, so that the mass settles down and packs closely about the plunger. The space left unfilled about the carbon should be filled with a mixture composed as follows:

These proportions may be measured in a tin cup, a table-spoon, or any other small receptacle. Note that the measurement by parts is always by bulk and not by weight.

Do not fill the zinc cup to the top, but leave an inch of space, so that half an inch of sealing material may be added. See that the inside top edge of the zinc cup is clean; then melt some tar or pitch and pour it over the top of the electrolyte, so that it binds the zinc cup and carbon into a solid form. Drive an awl down through the capping material when it is nearly dry, and leave the holes open for the escapement of gases.

Give the outer surface of the zinc cells a coat of asphaltum varnish, and wrap several thicknesses of heavy paper about them to prevent contact and short-circuiting. Protect the bottoms in a similar manner, and as a result you will have a cell that will appear as shown in [Fig. 18] B. A battery of cells powerful enough for any light work can be made by connecting the cells in series, each having an electro-motive force of one and a half volts, with an internal resistance of less than one-third of an ohm.

Chapter III
PUSH-BUTTONS AND SWITCHES

Push-buttons

Push-buttons and switches are a necessity in every home where electric bells, lights, or fans are used, for with them connections are made or broken. The telegraph-key and the commutators on a motor and dynamo are only improved forms of the push-button, and this simple little device is really an indispensable part of any electrical equipment.

The simplest form of push-button is a bent piece of tin or thin sheet-metal screwed fast to a small block of wood, as shown in [Fig. 1]. Under the screw-head one end of a wire is caught, and the other wire end is secured by a washer and a screw driven into the block directly under the projecting end of the strip of metal. By pressing a finger on the tin it is brought into contact with the screw-head under it, and the circuit is closed; on releasing it, the tin flies up and the circuit is opened again.

An enclosed push-button is shown in [Fig. 2]. It is made of the cover or body of a wooden box, a spool-end, and several other small parts. A round piece of thin wood is cut to fit inside the box and so form the base for the button. On this the spring strip is attached with screws, and the wire ends are made fast, as shown in [Fig. 3]. The wires are carried through the bottom of the base and along grooves to the edge, and thence to their final destination. The end of a spool is cut off and glued to the top of the box, as shown in [Fig. 2], and a hole is made in the box to correspond in size with that in the spool. Through this aperture the button (cut from a wooden dowel or shaped out with a knife) passes, so that the end projects about a quarter of an inch beyond the spool. To prevent the button from falling out, a small steel nail should be driven across the inner end, or a washer may be tacked to the end of the stick, as shown in [Fig. 4].

The button is mounted by screwing the base fast to the door or window casing, it being understood that the wires have been first arranged in place. The button is then set in the hole and the cap is placed over the base, covering it completely. By means of small screws, passed through the rim of the box and into the edge of the base, the cap is held in place. A coat of paint or varnish will finish the wood-work nicely, and this home-made button should then answer every requirement.

Switches and Cut-outs

In electrical equipment and experimental work, switches and cut-outs will be found necessary, particularly so for telegraph and telephone lines. Care should be taken to construct them in a strong and durable fashion, for they will probably be subjected to considerable wear and tear.

A simple switch ([Fig. 5]) is made from a base-block of wood three inches long, two wide, and half an inch in thickness, together with some small metal parts. It has but one contact-point, and that is the brass-headed tack (T in [Fig. 5]) driven through the binding-post, the latter being a small plate of brass, copper, or even tin screwed to the base-block. The end of a wire is caught under the screw-head before it is driven down. A similar binding-post is arranged at the lower side of the block, and the movable arm is attached to it with a screw. Between the arm and the post-plate there should be a small copper washer, to make it work more easily. The arm is cut from a thin piece of hard sheet brass or copper (tin or zinc will also answer very well), and at the loose end the half of a small spool is attached, with a brass screw and washer, to serve as a handle. The end of the screw that passes through a hole in the arm is riveted to the under side to hold it securely in place. This arrangement is shown in [Fig. 6].

The under edges of the arm may be slightly bevelled with a file, so that it will slip up easily on the oval head of the brass tack. The drawing shows an open switch; when the circuit is closed the arm rests on the tack-head. By means of small screws this switch-board may be fastened to a table or to any part of the wood-work in a house.

In [Fig. 7] a complex switch is shown. This is the principle of the shunt-box switch, of the resistance-coil, and also of the commutators of a motor. A motorman’s controller on a trolley-car is a good example of the shunt, and, with it and the resistance-coils, the car can be started, stopped, or run at any speed, according to the current that is admitted to the motor.

The complex switch is made in the same manner as described for the single switch, except that any number of binding-posts may be employed, arranged on a radial plan, so that the end of the arm will rest on any tack-head at will. Bells in various parts of the house may be rung by this switch, or it may be coupled with a series of resistance-coils to control any amount of current.

The simple cut-out ([Fig. 8]) is constructed in the same manner as the simple switch, except that there are two points of contact instead of one. This is the principle of the telephone and telegraph instrument wiring, so that a bell or sounder may be rung from a distance. The arm is then thrown over and the bell cut out, allowing the “phone” or key to be brought into use. In lifting the transmitter from the hook on a telephone, a cut-out is operated and the bell circuit is thrown out of action. It is in operation again directly the transmitter is returned to the hook. The switch cut-out ([Fig. 9]) is inactive when the arm is in the position shown in the illustration; but when it is thrown over (as shown by the dotted line) it connects the poles at opposite ends of the board. It may be thrown over in both directions, and is a useful switch for many purposes.

For strong currents the lever-switch, that rests on a brass tack-head, will not be suitable, as the switch-bar must be held firmly in place to make a perfect connection. Strong currents throw weak switches open, causing an open or broken circuit.

A single pole-switch, to carry a current up to one hundred and twenty-five volts and twenty-five amperes, is shown in [Fig. 10]. This consists of a base-block, a bar which is attached to the vertical ears of a binding-post, and a clutch that will hold the bar when it is pressed down between the ears.

The base-block should be made from some non-conducting material, such as soapstone, marble, or slate. If a piece of soapstone can be procured, that will be just the thing, since it is easily worked into the proper shape and size. Soapstone may be sawed and smoothed with a file; it is easily bored into with a gimlet-bit, and it is one of the best non-conducting substances. The base for this switch is six inches long, two inches wide, and as thick as the soapstone happens to be—say three-quarters of an inch. The top edge may be bevelled for the sake of appearance or left square.

Two pieces of heavy sheet copper or brass are to be cut as shown at A in [Fig. 11]. The ears are half an inch wide, and the total height of the strip is two inches and a half, while the part with two holes in it side by side is one inch and a quarter long, including the half-inch width of the vertical strip. With round and flat-nosed pliers bend the long ears into shape, so as to form a keeper for the bar which is then to be riveted in place. Omit the holes at the ends of the long ears in the other plate; then bend it into shape to form a clutch that will hold the bar when it is pressed down between the ears. These binding-posts should be made fast to the base-block with brass machine-screws and nuts, which will fit in countersunk holes in the bottom of the soapstone. If hard-wood is used for the base, ordinary brass wood-screws will answer very well.

The connection-bar is cut from metal the same thickness as that employed for the binding-posts and clutches; it should be shaped so as to appear as shown at B in [Fig. 11]. A handle should be driven on the slim end, and where the lower edge enters between the ears of the clutch, the corners of the bar should be rounded with a file. Countersunk screw-holes are bored in the base, so that it can be made fast to the wood-work.

A double pole-switch is shown in [Fig. 12], and in general construction it is similar to the single pole-switch described above. The binding posts and bars are cut and bent from the patterns A and B in [Fig. 11]; but in this case the long, slim ends of the bars are omitted. A short turn is made at the handle end of each bar and a hard-wood block is placed between the bar-ends and held in position with screws driven through holes made in the bars and into the ends of the block. A handle is made fast to the middle of the block with a long and slim wood-screw; or a steel-wire nail may be passed through the handle and block, a burr slipped over the end opposite the head, and the small end riveted fast. When the binding-posts (to which the ends of the bars are attached) are screwed onto the base, be sure and see that the bars are parallel and the same distance apart at both ends. In like manner, when the cleat binding-posts are made fast, see that they are directly in line with the bars, so that the yoke will drop into the spaces between the ears without having to be pulled to one side or the other. This is a very useful switch for strong currents, and may be placed close to a dynamo, so that the current in both wires may be cut out at once.

Table-jack Switches

A table-jack switch is a most convenient piece of apparatus where several lines of bells, alarms, or telephone circuits are to be switched on and off.

The single table-jack switch, shown in [Fig. 13], is made of a hard-wood block three-quarters of an inch thick, five inches wide, and seven inches long. It is to be smoothed and varnished, or given several coats of shellac. At the four corners small holes are made to receive slim screws, and at one end of the block five short metal plates are screwed fast, with the heads of the screws countersunk, so that they will be flush with the top of the plates. These small plates should be half an inch wide and one inch long, and may be of brass, copper, or tin. But if they are of tin the plates are made of a longer strip tacked to the board and then bent over, as shown at A in [Fig. 14]. They will therefore form short springs, the upper parts of which will rest against the long spring-arms. From spring brass or copper five arms are to be cut and shaped, as shown in [Fig. 13]. Holes are made at one end of each, and others again two inches from these, through which to pass screws.

Screw-eyes are passed through copper washers and the end holes in the strips, and then screwed into the wood plate. These will act as binding-posts, while the second line of screws will hold the plates down to the base. The arms should be bent, so that when the screws are driven down the lower edge will press on the small plates under them.

The outlet wires are attached to the binding-posts at the head of the block, and the plug (A in [Fig. 13]) is inserted between the arm and plate at the foot, so that contact and connection are made. This plug is a small plate of metal to which the end of a flexible wire is made fast. It should be of copper or brass, but for light work a strip of tin may be bent over with the wire caught between the plates and a copper tack passed through the sides and riveted, as shown at B in [Fig. 14].

A double jack-switch ([Fig. 15]) is made on the same general plan as the single, but it has no binding-posts. A block of the same size is used, and two rows of short plates are made fast at each end. The arms are made with two screw-holes near the middle, as shown in [Fig. 15], and through these holes screws are driven to hold the arms down to the base. Several plugs are used for each end, so that the in and out lines can be shifted, and from one to four lines used at a time.

TABLE-JACK SWITCHES

A convenient slip-switch for single or double line work is shown in [Fig. 16]. This consists of a small wooden base, on which a brass arm and handle are screwed fast and connected with a binding-post (A in [Fig. 16]). A slip-plate is made from a piece of sheet-brass and bent so as to form a pocket into which the arm will fit. This pocket piece is connected with the binding-post B. When the switch is thrown out the circuit is broken, unless a contact-point, C, is provided, from the under side of which a wire leads out to a second circuit. When the switch is in place, as shown in [Fig. 16], the circuit is closed through A and B; but when the arm is thrown out the circuit through A and B is broken and that through A and C is closed.

Binding-posts and Connectors

To make quick connections between wires and other parts of electrical apparatus, binding-posts are the most convenient device, since the turn of a screw binds or releases a wire instantly. Binding-posts may be made in many forms, but the simple ones that a boy will need can be made from screw-eyes, burrs, stove-bolts, and nuts, together with thin strips of metal and nails.

Five simple posts are shown in [Fig. 17]. A is made from a screw and two burrs, B from a screw-eye and two burrs, and C from a thin plate of metal and two screws, with oval or round heads. This last, however is more of a connector than a binding-post. The ends of the wires to be connected should be caught under the screw-heads or between the burrs before the screws are driven down.

In D a simple arrangement of a stove-bolt and two nuts is shown. The under bolt is screwed down tightly against the wood, and under the head a wire is made fast, so that another wire may be caught under the upper nut. If a small thumb-nut can be had in place of the plain nut, it will be easier to bind the upper wire. In [Fig. 17] E a thin strip of metal may be folded over, and at the loose ends a hole should be punched through which a screw-eye will pass. The metal is held to a wood base with a screw, under the head of which a wire is caught. The second wire end is slipped between the metal plates, and a turn of the screw-eye will bind and hold it securely.

Connectors are employed to unite the ends of wires temporarily, and are made in many forms. A simple and useful one is made from a piece of spiral spring fastened to a block of wood by two staples, as shown at [Fig. 18] A. The ends of the wires are pressed down into the coils of the spring and are held with sufficient security for temporary use. Another connector is made from a block of wood, a strip of thin metal, and two screw-eyes ([Fig. 18] B). The metal is bent around the ends of the block, and through holes made in the ends of the strip screw-eyes are driven into the block. When the ends of wires are slipped under the metal, a turn of the eyes will hold them fast, as shown at [Fig. 18] B.

A short bolt threaded at each end and provided with four nuts will also act as a connector. The inner nuts are screwed on tightly and the outer ones are loose, so that when wires are placed between them they may be tightened with the fingers, as shown at C in [Fig. 18]. These are a few simple forms of connectors; the ingenious boy can devise many others to suit his needs and ideas.

Lightning-arresters and Fuse-blocks

All lines of exposed wire that run from out-doors into the house should be provided at both ends with lightning-arresters, particularly if they are telephone or telegraph lines, burglar alarms, or messenger call-boxes. In many instances where unprotected telephone lines have been the plaything of lightning, painful accidents have happened, and it is only the part of prudence to provide against them. It is better to have an arrester at both ends of a line, and as the cost is insignificant it is hardly worth considering as against its feature of safety.

Lightning-arresters may be constructed in many ways and of different materials; the ones here shown and described are easily made and efficient. The principle of all arresters is simply a fuse which burns out whenever the wire is carrying a greater amount of current than is required for the proper working of the apparatus, thereby arresting the current and protecting the instruments from destruction. Induction-coils, relays, fine windings on armatures, or a magnet helix are quickly destroyed if a too powerful current is permitted to pass through them, and it is therefore advisable to protect them. When a fuse burns out under a trolley-car, or in the shunt-box of a motor-car or engine, it is because a greater amount of current is trying to pass in than the motor will safely stand. When a fuse “blows out,” the apparatus or motor is put out of commission until the fuse is replaced, but the delicate mechanism and the fine wiring on the field-magnets or armatures are saved.

The simplest form of single pole-fuse is a fine piece of lead wire held between two binding-posts, as shown at A in [Fig. 19]. The lead wire may be of any length; but for small instruments, where a moderate current is employed and where there is a possibility of lightning travelling on the wire, the fuse should be from two to three inches long. For inside work, however, where it is to be used simply as a safety, the wire may be shorter and finer.

To make the lightning-arrester shown in [Fig. 19], cut out a hard-wood block five inches long, an inch wide, and half an inch thick. Give this several coats of shellac; then place a piece of mica, or asbestos paper, over the top of the block, and make it fast with thick shellac to act as a glue. From small pieces of copper or brass cut two plates one-half by one inch, and drill holes in them to take screws and screw-eyes. Place copper burrs under the screw-eyes for connectors, and drive two brass screws half-way down in the block through the holes at the inner ends of the binding-post plates. See that these screws fit snugly in the holes in the plates so that contact is perfect. If the holes are too large and the screws fit loosely, two copper burrs will have to be used and the screws driven in, so that the heads bind the burrs on the ends of the fuse-wire. From an electrician, or supply-house, purchase a few inches of fine lead fuse-wire—say Nos. 20, 22, or 24—and twist the ends of a length around the screws, as shown in the drawing. Perfect contact should be had between the lead wire and the screws; by way of precaution, a bit of solder will dispel all doubt. Just touch the point with a little soldering solution; then apply a soldering-iron having a drop or two of solder on the end.

Perfect connection is absolutely necessary for telephone, telegraph, or annunciator work, and where there is a lightning-arrester and the line is not working well, the trouble may often lie in the poor contact of lead and brass or copper, or possibly in using wire that is too fine. Lead is a very poor conductor, and a fine wire would act as a check. For a test, first insert a piece of copper wire to see that the line is working properly; then use lead wire of sufficient size to carry the current as well as the copper did. The action of metals and wire, as current retarders, will be explained in the [chapter] on resistance and resistance-coils.

For general commercial use the base-blocks of all lightning-arresters should be made of porcelain, slate, or some of the composition non-conductors, such as moulded mica, silex and shellac, or fibre. As these are not always available, wood, with a covering of mica, will answer every purpose and can be readily adapted for use.

The apparatus pictured in [Fig. 19] is known as a single-pole lightning-arrester, and is the simplest form of this kind of electrical paraphernalia. In [Fig. 20] a double-pole arrester is shown. This is constructed in the same manner as described for the single one. The block is five inches long, two inches wide, and half or five-eighths of an inch thick. A countersunk hole is made in the middle of all the lightning-arrester blocks through which a screw can be passed to hold the apparatus fast in any desired location.

In [Fig. 21] another form of fuse is shown. It is made from a piece of mica three-quarters of an inch wide and four inches long, two pieces of thin sheet-copper, and a piece of lead fuse-wire. The copper is three-quarters of an inch wide, and one piece of it is bent in the form of a V, as shown at A in [Fig. 21]. One end of the mica strip is dropped in the V, and with a pair of pliers the V is closed up by pinching it at the bottom. To further insure its staying in place, the top and end, or open edges, should be soldered. Punch a small hole through the copper ends, at the inside edge, slip the ends of the fuse-wire in them, and touch the union with a drop of solder to insure perfect contact. With shears and file cut a U from the side of one copper band and from the end of the other; these will allow the copper ends to pass under the heads of screws, thus avoiding the necessity of removing the entire screw from the block in order to set the fuse in place.

LIGHTNING-ARRESTERS AND FUSE-BLOCKS

The block on which this fuse is held is shown in [Fig. 22], and is made in a similar manner to the one shown in [Fig. 19], except that the metal plates are a trifle longer and are bent up, as shown in the drawing. Thus the mica fuse-plate will be elevated above the block. If the brass or copper used for the binding-post plates is too thin to stand the pressure of the screws when the fuse ends are screwed fast, put a few burrs on the screws below the plates; then the pressure of the screws cannot bend down the extending ears of the plates and make an imperfect contact.

Another form of fuse-block is shown in [Fig. 23]. The same sort of a fuse is employed as shown in [Fig. 21], but without the U cuts at the ends. The clutches are made by binding brass or copper plates, as shown in the drawing; they should then be screwed fast to a base-block five inches long, one inch and a half wide, and five-eighths of an inch thick. The opening between them should just admit the copper ends of the fuse, and pressure should be used to force the fuse in place so that the contact will be perfect.

Still another form of fuse is shown in [Fig. 24]. This last may more properly be called a non-sparking fuse, for the lead wire is encased in a glass tube, and when it fuses no sparks fly and no small pieces of melted metal can get away from the inside of the tube. The plug is made from a piece of glass tube half an inch in diameter, two metal caps, and a short piece of lead wire. The metal caps are of thin sheet-copper, and are caught at the edges with solder. One end of the lead fuse-wire is passed through a hole in the end of a cap and soldered, as shown at A in [Fig. 24]. The wire is then passed through the tube and the cap placed over one end of it. This is repeated at the other end and the wire soldered fast. As a result, you will have a glass tube with metal caps held on the ends of the tube, by means of the thin lead wire which runs through the middle of the tube. The base-block to which this fuse-plug is attached is of wood one inch and a half wide, five or six inches long, and five-eighths of an inch thick. Two metal straps are made and screwed fast to the block, and the circuit wires are attached under the copper burrs and held down by the screw-eyes.

To place or replace a fuse-plug, unscrew the eyes and raise each strap slightly, so that the copper cap ends will pass under them. A turn or two of the eyes will clamp the plug in position and at the same time bind the circuit wires.

A spring lightning-arrester is shown in [Fig. 25]; it is simply a modified form of that shown and described in [Fig. 19]. The base-block is five by one-and-a-quarter by five-eighths of an inch, and is properly protected by a sheet of mica or asbestos. The two metal plates are cut for the binding-posts and screwed in place with screws, burrs, and screw-eyes. From spring-brass wire bend a hook and slip one end of it under the screw-head at the left side of the block. From a longer piece of wire make two or three turns around a piece of wood half an inch in diameter; then form a hook at one end and a turn at the other, so that it can be made fast under the screw-head of the binding-post. When at rest, the spring-hook should stand in an upright position, but when sprung and tied it occupies the position shown in the drawing. The spring-hook is to be bent down so that the two hooks are brought within an inch of each other. They are held in this position with a piece of lead fuse-wire. This last is given a turn about the hooks and one or two turns about itself, close to each hook, to prevent the spring from tearing itself away. When the wire is fused by a current the spring-hook flies up and away from possible contact with the short hook attached to the opposite binding-post. This is the construction for a single-pole-spring lightning-arrester; a double one is made in a similar manner, and the parts mounted on a wider block, as shown in [Fig. 20].

For doubtful currents, where there is no means of knowing how strong they are, a combined fuse and single-pole switch is shown in [Fig. 26]. This is nothing more than a combination of the apparatus shown in [Fig. 21], and the single-pole switch ([Fig. 10]). The base block is seven inches long and two inches wide. Or it may be made half an inch wider if it is to be bevelled at the top, as shown in the drawing. It should be three-quarters of an inch thick and provided with two countersunk holes for screws that will hold it in place on a ledge or against a casement. The little angles to hold the copper-ended mica fuse-plate are described for the apparatus pictured in [Fig. 21]. If it is desired that one of the ends should be provided with burrs and a screw-eye, the little plate of brass should be an inch long and an inch wide, with a half-inch-square piece snipped from one corner, as shown at A in [Fig. 26]. It is provided with two holes, and then bent on the dotted line, so that the part with the holes will lie on the block and the ear will stand in a vertical position. A reverse-plate made on this pattern will act as one side of the switch-bar clutch at the opposite end of the block. For the metal clutch and keeper at the middle of the block the metal plate (before it is bent) will appear as shown at B in [Fig. 26]. The long plate with two holes lies on the base, while the first ear (or the one without the hole) forms part of the clutch for the fuse end, the ear with the hole acting as one side of the bar-lever strap. An opposite plate to this forms the other side of the clutch and strap, and the two plates are screwed side by side, so that the fuse-plate will be held securely when pushed into place.

For the switch-bar use a piece of hard copper or brass four inches long, half an inch wide, and about one-eighth of an inch thick, or the same thickness as the copper straps at the ends of the mica fuse-plate. Bore a hole at one end of this bar, and with a copper rivet attach it between the two upright ears at the middle of the block. With a file cut away the two edges at the other end of the bar for a distance of an inch, so that the bar will have an end as shown at C in [Fig. 26]. Drive a small file-handle on this end and give it a coat or two of shellac; then bevel the lower edges of the bar with a file where it enters between the blades of the clutch. The circuit wires are made fast at both ends of the block, and the current travels through the binding-posts, the lead fuse-wire on the mica plate D, and the switch-bar. If the current is too strong, then when the switch-bar is pushed into the clutch the safety-fuse will burn out and save the apparatus; or it will arrest a flash of lightning.

Chapter IV
MAGNETS AND INDUCTION-COILS

Simple and Horseshoe Magnets

Every boy has a horseshoe magnet among his collection of useful odds and ends, and whether it is a large or small one its working principle is the same. If large enough it will lift a jack-knife, nails, or solid weights, such as a small flat-iron or an iron padlock. A horseshoe magnet is made of highly tempered steel and magnetized so that one end is a north pole and the other a south pole. In more scientific language these poles are known as, respectively, positive and negative. Once magnetized the instrument retains that property indefinitely, unless the power is drawn from it by exposure to intense heat, and even then, by successive heating and cooling, the magnetism may be partially restored.

An electro-magnet may be made of any scrap of soft iron, from a piece of ordinary telegraph-wire to a gigantic iron shaft. When a current of electricity passes through a wire a magnetic “field” is produced around the wire, and if the latter is insulated with a covering and coiled about a soft iron object, such as a nail, a bolt, or a rod, that object becomes a magnet so long as a current of electricity is passing through the coils of wire or helix. A coil of wire in the form of a spiral spring has a stronger field than a straight wire carrying the same current, for each turn or convolution adds its magnetic field to that of the other turns.

A simple form of electro-magnet is made by winding several layers of No. 20 insulated copper wire around a stout nail or a carriage-bolt; by connecting the ends to a battery of sufficient power, some very heavy objects may be lifted. A single magnet, like the one shown in [Fig. 1], is made with a piece of soft iron rod six inches long and half an inch in diameter, the ends of a large spool sawed off and worked on the rod, and half a pound of No. 20 insulated copper wire. The spool-ends are arranged as shown in [Fig. 2]. An end of the wire is passed through a hole in one flange when you begin to wind the coils, and when finished, the other end is passed through a hole at the outer rim of the same flange. This magnet may be held in the hands when in use; or a hand-magnet may be constructed of a longer piece of iron on one end of which a handle is driven and held in place with a nut and washer, as shown in [Fig. 3]. The wires from the coil pass through holes made in the handle and come out at the butt end, where they may be attached by connectors to the pole-wires of a battery. To protect the outer insulated coil of wire from chafing and a possible short-circuit, it would be well to wrap several thicknesses of stout paper around the coil and glue it fast; or a leather cover will answer as well.

SIMPLE AND HORSESHOE MAGNETS

A more powerful magnet may be made from a stout bolt, two nuts, and a wooden base, with about three-quarters of a pound of No. 18 insulated copper wire to wind about the body of the bolt. A block of wood an inch thick, four inches wide, and six inches long is provided with a hole at the middle for the bolt to pass through. A larger hole is made at the under side of the block so that a nut can be easily turned in it. A three-quarter-inch machine-bolt, with a square head, and seven inches long, is set in the block, head up, as shown in [Fig. 4]; and composition or thin wooden disks or washers are placed on the bolt to hold the coils of wire in place. The ends of the wire pass out through the bottom washer and are made fast to binding-posts on the block, and to these latter the battery-poles are made fast when the magnet is in use. Coils of wire may be wound on an ordinary spool, and the hole in the middle may be filled with lengths of soft iron wire. When a current is passing around the spool the wires become highly magnetic, but lose the magnetism directly the current ceases.

Horseshoe electro-magnets are made by winding coils on the ends of U-shaped pieces of soft iron, but the winding must be done so that the current will pass around them in opposite directions, otherwise you would have two negatives instead of a negative and positive. For a small horseshoe magnet a stout iron staple may be used, but for the larger magnets it would be best to have a blacksmith bend a piece of round iron in the desired shape.

A powerful horseshoe magnet may be made from a piece of tire-iron bent as shown in [Fig. 5] A; when wound with No. 18 wire it will appear like [Fig. 5] B. A volt or two of current passing through the coils will render this magnet powerful enough to lift several pounds.

For bells, telegraph-sounders, and other electrical equipment requiring the horseshoe or double magnet, several kinds may be used, but the simplest is constructed from two carriage or machine bolts and a yoke of soft iron, as shown in [Fig. 6]. The yoke is five-eighths of an inch in width, two inches and a half long, and provided with two three-eighths-inch holes, one inch and a half apart from centre to centre. Two-inch carriage or machine bolts are used, and they should be three-eighths of an inch in diameter. The nuts are turned on the thread far enough to admit the yoke, and then another nut is applied to hold it in place and bind the three pieces into one compact mass. Wooden spool-ends or composition washers are placed on the bolts to hold the ends of the wire coils in place, and the winding may be done on each bolt separately and locked to the yoke after the winding is completed. Double cotton-insulated No. 20 or 22 copper wire should be used for the coils.

It is a tedious and bothersome job to wind a coil by hand, and if possible a winder should be employed for this purpose. Several varieties of winders are on the market, but a simple one for ordinary spools may be made from a stick held in an upright piece of wood with staples. This idea is pictured in [Fig. 7], where the round stick is shown cut with two grooves into which the staples fit. One end of the stick is made with a square shoulder, so that a handle and crank can be fitted to it. A few wraps of wire are taken around the crank to prevent it from splitting, and it is held to the round stick with a slim steel nail. The opposite end of the round stick is shaved off so that it will fit snugly in the hole of a spool; if it should be too small for some spools, a few turns of cord around the small end will make it bind. The block to which the shaft and crank is attached may be held in a vise or screwed to the edge of a table.

Induction-coils

A simple induction or shocking coil may be made of a two-and-one-half by five-sixteenths-inch bolt, a thin wooden spool, and two sizes of insulated copper wire. An induction-coil is a peculiar and wonderful apparatus; it figures largely in electrical experimenting and is a part of every complete equipment.

A piece of curtain-pole may be used for the spool. First bore a five-sixteenths-inch hole through the wood to receive the bolt; then in a lathe turn it down into a spool with less than one-eighth of an inch of wood about the hole and with flanges about one-eighth of an inch in thickness. Smooth the spool with sand-paper, while it is still in the lathe, and give it a thin coat or two of shellac.

Slip the spool on the winder ([Fig. 7]) and wind on three layers of No. 24 cotton-insulated copper wire, taking care to wrap the coils evenly and close. Bring six inches of the ends out at either end of the spool through small holes pierced in the flanges; then wrap several thicknesses of brown paper around the coil. A current passing around this three-layer coil will magnetize the bolt. This is the primary coil and the one through which the battery current will pass.

A secondary coil is now made over the primary one with eleven or thirteen layers of No. 30 insulated copper wire. It will take some time to carefully put on these layers, and when doing so mark down each layer so as to keep an accurate count, for there must be the right number of layers to make the coil act properly. No. 30 wire is quite fine, and if the layers are not inclined to lie smooth, make a wrap or two of brown paper between each three layers. Bring six inches of each end of the wire out from the flanges of the spool, and to protect the outer coil wrap paper about the coils and attach it fast with thread or paraffine. Slip the bolt through the hole and screw the nut on the threaded end. Cut out a wooden block four inches long, three inches wide, and three-quarters of an inch thick, and with two thin metal straps and screws attach the coil to the middle of the block, as shown in [Fig. 8]. Make four binding-posts and screw them fast at the corners, and to A and B of [Fig. 8] attach the ends of the heavy wire from the primary coil, and to C and D of [Fig. 8] the ends of the fine wire from the secondary coils. The induction-coil is now ready for any use to which it may be put, and by mounting it on the block with the delicate wire ends attached to the binding-posts, it is in less danger of damage than if the wire ends were left loose for rough-and-ready connections.

In order to get a shock from this coil it will be necessary to have a pair of handles and a current interrupter. The handles may be made from two pieces of tin rolled into the form of cylinders to which wires are soldered. Or, better yet, use pieces of thin brass tubing an inch in diameter. The buzzer shown in [Fig. 9] may be employed for a current interrupter, and a bichromate battery will furnish the current.

In order to make the connections, the wires from the handles are attached to the binding-posts C and D in [Fig. 8]—that is, to the wires of the secondary coil. One spool of the battery is connected with A of [Fig. 8] and the other with A of [Fig. 9]. A wire connects C of [Fig. 9] with B of [Fig. 8], and the circuit is closed. The buzzer now begins to vibrate, and any one holding the handles will receive a shock the intensity of which depends on the strength of the batteries. A switch should be introduced somewhere in the circuit, so that it may be opened or closed at will; a good place for it is between a battery-pole and the binding-post A in [Fig. 8].

If the shock is too intense it may be weakened by drawing the carbon and zinc poles partly out of the bichromate solution; or a regulator may be made of a large glass tube and a glass preserving-jar filled with water. If the tube cannot be had, an Argand gas-burner chimney will answer as well.

Solder a wire to the edge of a small tin or copper disk, as shown in [Fig. 10], on which the chimney rests at the bottom of the jar, and another wire to a tin box-cover with some small holes punched in its top, this latter being suspended within the chimney. This second wire is passed out through a cork at the top of the chimney made of a disk of cardboard and a piece of wood. One wire is connected with A of [Fig. 8] and the other with a battery-pole. This apparatus acts the same as a resistance-coil, and by raising or lowering the box-cover the current is increased or diminished. The closer the cover comes to the disk the stronger the current, as there is less water for the electricity to pass through and therefore less resistance; while if the cover touches the disk the current flows as freely as if there were no regulator and the wires ran directly to the cell.

An apparatus comprising a coil, an interrupter, or armature, and a switch may be set on one block, and the arrangement of the several parts is clearly shown in the drawing of the complete galvano-faradic apparatus ([Fig. 11]). The block should be six inches long, four inches wide, and seven-eighths of an inch in thickness.

The coil is made as described for [Fig. 8], the spool being three inches long and one inch and a quarter in diameter. A carriage-bolt three inches and a half long and five-sixteenths of an inch in diameter, with a bevelled head, is made fast in the spool, and this coil is strapped to the block with two metal bands and screws. Two binding-posts (A and B of [Fig. 11]) are arranged at the upper corners, and to these the ends of the secondary coil wires are attached. Two more binding-posts (C and D of [Fig. 11]) are arranged at the lower side and provided with a switch to open and close the circuit. One of the primary coil wires is made fast to C, and the other one to a block which contains the set-screw that bears against the vibrating armature. Its arrangement and the wire connection is explained in [Fig. 9] B.

An armature of thin brass or tin is made and attached to a block (E in [Fig. 11]). At the loose end that is opposite the bolt-head several wraps of tin are made and soldered fast, or a small block of soft iron may be riveted to the armature. It must be of iron or tin, however, so as to be attracted by the electro-magnetized bolt-head. This arrangement may be seen in [Fig. 12]. Attach a thick piece of paper over the bolt-head, so that the lug at the end of the armature will not adhere to it through residual magnetism.

In regular galvano-faradic machines the current regulator is formed of a hollow cylinder which is drawn from the core of the coil; but in this simple machine the water-jar regulator may be connected between a pole of the battery and the binding-posts (D or E of [Fig. 11]). The wires of the handles are attached to posts (A and B of [Fig. 11]), and when all the wires are in place and the current turned on by means of the switch, the vibrator begins to work and the shocking-current is felt through the handles. By means of the regulating-screw that bears on the armature, the number of vibrations may be increased or diminished, but for faradic purposes the vibrations should be as quick as possible. Much amusement may be had with this apparatus, and a large number of people may be given a shock by getting them to join hands when standing or sitting in a circle.

An Electric Buzzer

This piece of apparatus is, in theory, nothing more than the electric bell, and might properly be included in [Chapter V.], on Annunciators and Bells. But since it is the logical development of principles just laid down, it has been thought best to give it its present position.

The electric buzzer is constructed on the principle of the telegraph-sounder, but instead of making a single click or stroke the current is made to act on the armature and keep up a continuous motion so long as the electricity passes through the helix of the cores, the armature, and the contact-points of the apparatus.

A buzzer has the same movement as an electric bell with the ringing apparatus removed. For offices, houses, and quiet calls it is often preferred to the loud ringing of a bell.

The electric buzzer shown in [Fig. 13] is easy to make; it is operated by the aid of a cell and a push-button. Cut a base-block three inches and a half wide, five inches long, and three-quarters of an inch thick, and mount a horseshoe magnet made of bolts and a yoke and coils about at the middle of it, as shown in [Fig. 9]. The magnet is held to the base by a flat wooden cleat and a screw passed down through a hole in the cleat and into the base, between the coils. An armature of soft iron, two inches long and half an inch wide, is riveted to a piece of spring-brass, as shown in [Fig. 14] A, and the end is bent so that it will fit around the corner of a block to which it is held fast with two screws. This armature is mounted so that there is a space one-sixteenth of an inch wide between it and the bolt-heads, as you can see in [Fig. 9]. The brass is bent out slightly and runs parallel with the armature for one inch and a quarter. Against this the end of the screw mounted in block B [Fig. 9] rests.

The block B is a small piece of hard-wood screwed fast to the side of the base to hold the set-screw and also the wire that comes from the outside of the upper coil. A small hole is made in the edge of the block and the wire passed in, so that the end rests in the screw-hole as shown by the dotted line. When the screw is placed in the hole and turned, it comes into contact with the wire and makes a connection. This block and its attachment is shown in [Fig. 14] B.

On the base, near the armature-block, a binding-post is made fast, and the current, passing in through the wire A in [Fig. 9], goes through the coils and around to the screw B, then through the armature to the block, and out through the wire C. In its circuit the bolts are magnetized, and they draw the armature, but the instant they do so the loose spring-brass end is pulled away from the screw-point B and the circuit is broken, the bolts cease to be magnetized, and the armature flies back under the influence of the spring-brass neck at D. The loose brass end, on touching the screw-point, conducts the current through the coils again, with a continual vibrating action, so long as the electric current is passing in at A and out at C. The greater the volume of current the greater the number of vibrations, and to properly regulate the contact the set-screw B must be adjusted at the right point. Paste pieces of heavy paper over the heads of the bolts to overcome residual magnetism.

A single electric bell is made the same as a buzzer, but continuing on from the end of the armature a wire or rod is mounted with a ball at the end which strikes the bell as the current causes the armature to vibrate. The bell-block may be made longer, and a bell from an old clock or a bicycle should be mounted at the proper place on a wooden dowel driven into the base. A screw passes through the hole at the middle of the bell and into the top of the dowel. The ball at the end of the rod may be made of brass with a hole in it, and a drop of solder will hold it in place. Or it may be made of wire wound round the end and soldered into a compact mass.

A Large Induction-coil

As has been said, the induction-coil is one of the mysterious phenomena of electrical science. While its practical value is known and recognized in all branches of voltaic electricity for use in transforming currents, its actual workings have never been clearly explained.

The construction of a small induction-coil was explained in the description of a shocker or medical battery. For bigger equipments, wireless telegraphy and other uses, a large induction-coil will be necessary, and the following illustrations and descriptions should enable the young electrician to construct an apparatus that will be both simple and efficient in its working.

For the tube (in which to wind the primary coils) obtain a piece of red fibre-tubing, one inch inside diameter and not more than one-eighth of an inch in thickness. The length should be ten inches. If fibre cannot be had use a paste-board tube.

From white-wood, half an inch in thickness, saw two blocks four inches square and in the centre of each cut a hole so that the tube will pass through it and fit snugly. Some shellac and a few slim brass escutcheon pins will hold the blocks in place, as shown at [Fig. 15]. The wood blocks and fibre or paper tube should be treated to several successive coats of shellac to give them a good finish and prevent the absorption of moisture. Four binding-posts, with wood screw-ends, are to be made fast at the top edges of the end-blocks, as shown at [Fig. 15]. Holes bored in the blocks near the foot of the binding-posts will admit the ends of the coil-wires so that contact can be made. The ends of the conductor-wires should then be placed in the holes in the binding-posts and held in place with the thumb-screws.

The primary coil is made by winding four layers of No. 20 insulated copper wire on the tube and between the end-blocks, as shown at [Fig. 16]. Each layer must be wound evenly, and the strands should lie close to each other. When the first layer is on give it a coat of shellac; then wrap a piece of thin paper about it and give that also a coat of shellac. When the second layer is on repeat the operation of shellacking and paper-coating, and continue with the third layer. When the fourth layer is on give the coil a double wrap of paper and two or three coats of shellac to thoroughly insulate it and keep out all moisture. The winding may be done by hand, but it is much easier to do it on a winder or reel, which can be operated to revolve the core, the wire unwinding from its original spool as it is wound on the tube.

A convenient winder may be made on a base-board which can be clamped to a table or bench. The board is twelve inches long, eight or ten inches wide, and seven-eighths of an inch thick. Two uprights, three inches wide, ten inches long, and three-quarters of an inch thick, are screwed and glued to the ends of the base-board. A notch is cut in the top of the end-boards, into which the spindle or shaft can rest; and at the top of the end-pieces two small plates of wood or metal are screwed down to hold the spindle in place when the tube and ends are being revolved. A small hole, bored in each upright end two inches above the top of the base-board, will admit a rod on which a spool of wire can revolve, as shown at [Fig. 17].

Two plugs of wood, shaped like corks, are made to fit in the ends of the fibre-tube. A hole is bored through each one so that a wire or rod spindle will pass through them and fit tightly. One end of the rod is bent and provided with a small wooden handle, by means of which the core may be revolved.

This winding-rack makes it easy to handle the core-tube while putting on the layers of wire, and it holds the tube securely while the wraps of paper and shellac are applied.

The secondary coil is laid over the primary, and should be of Nos. 30 to 36 insulated copper wire. The finer the wire the higher the resistance and the longer the spark, but nothing heavier than No. 30 should be used.

Begin by making one end of the wire fast to a binding-post; then turn the core-tube with one hand, holding the wire in the other. Take care not to bind the wire nor stretch it, but wind it on smoothly and evenly, like the coils of thread on a new spool of cotton or silk. Be very careful to avoid kinks, breaks, or uninsulated places in the wire. Should the wire become broken, give the coil a coat of shellac to bind the wound strands; then make a fine twisted point and cover it with the silk or cotton covering, with a coat of shellac to hold it in place, and proceed with the winding. Between each layer of wire place a thin sheet of paper and coat it with paraffine, or shellac, to make a perfect insulation; then proceed with the next layer.

With a battery and small bell test the wire layers occasionally to see that everything is all right, and that there are no breaks or short circuits. This is very necessary to avoid making mistakes, and, considering the time and care spent in winding the coils, it would be a great disappointment if the coil were defective.

About one pound and a half of wire should constitute the secondary coil, and, if possible, it is best to have it in one continuous strand, without splices.

Over the last coil, after the winding is completed, several thicknesses of paper should be laid and well coated with shellac between each wrap. This is a protector to insure the fine wire strands from damage. To improve the appearance of the coil a wrap of thin black or colored leather may be glued fast, with the seam or point at the under side.

The ends of the wires forming the primary coil should be made fast to the binding-posts at one end, while those of the secondary coil should be attached to the posts at the other end.

For the core, obtain some soft iron wire, about No. 18, and cut a number of lengths. Straighten these short wires and fill the tube with them, packing it closely, so that the wires will remain in place under a mutual pressure. It is better to make a core of a number of rods or wires rather than to have it of one solid piece of soft iron.

Now, from hard-wood, cut a base three-quarters of an inch thick, five or six inches wide, and twelve inches long. Attach the coil to the base by means of screws passed up through the board and into the lower edges of the end-blocks. The wood is to be stained and given several successive coats of shellac.

Now connect the wires of a battery to the binding-posts in contact with the primary coil, and attach two separate wires to the secondary coil binding-posts. Bring these ends near to each other, and a spark will leap across from one end to the other, its size or “fatness” depending on the strength of the battery. The completed apparatus is shown at [Fig. 18].

In producing a long spark a condenser is an important factor; it is used in series with an induction-coil. There are several forms of condensers, but perhaps the simplest and most efficient is the Fizeau condenser, which is made up of layers of tin-foil with paraffined paper as separators.

From a florist’s supply-house purchase one hundred and fifty sheets of tin-foil seven by nine inches, or sheets that will cut to that size without waste; also ten or twelve extra sheets for strips. At a paper supply-house obtain some clear, thin, tough paper about the thickness of good writing-paper. Be careful to reject any sheets that are perforated or have any fine holes in them. The sheets should be eight by ten inches, or half an inch larger all around than those of the tin-foil. The paper must be thoroughly soaked in hot paraffine to make it moisture-proof and a perfect non-conductor. This is done by placing about two hundred sheets on the bottom of a clean tin tray, or photographic developing-dish of porcelain. Don’t use glass or rubber. After placing some lumps of paraffine on the paper, put the tray in an oven so as to dissolve the paraffine and thoroughly soak the paper.

Open the oven door and, with a pin, raise up the sheets one at a time, and draw them out of the liquid paraffine. As soon as it comes in contact with cool air the paraffine solidifies and the sheet of paper becomes stiffened. Select each sheet with care, so that those employed for the condenser are free from holes or imperfect places.

From pine or white-wood, a quarter of an inch in thickness, cut two boards, eight by ten inches, and give them several good coats of shellac.

To build up the condenser, lay one board on a table and on it place two sheets of paraffined paper. On this lay a sheet of tin-foil, arranging it so that half an inch of paper will be visible around the margin. From the odd sheets of tin-foil cut some strips, one inch in width and three inches long. Place one of these strips at the left end of the first sheet of foil, as shown at [Fig. 19]. Over this lay a sheet of the paraffined paper, then another sheet of the foil. Now on this second sheet of foil lay the short strip to the right end, and so proceed until all the foil and paper is in place, arranging each alternate short strip at the opposite end. Care must be taken to observe this order if the condenser is to be of any use.

When the last piece of foil is laid on, with its short strip above it, add two or three thicknesses of paper, and then the other board. With four screw-clamps, one at each corner, press together the mass of foil, paper, and boards as closely as possible, then bind the boards about with adhesive tape, or stout twine, and release the clamps. Attach all the projecting ends of foil at one side by means of a binding-post, and those at the other end with another binding-post. The complete condenser will then appear as shown in [Fig. 20].

When in operation one wire leading from the secondary coil should be connected with a binding-post of the condenser, so that it is in series.

The object of the condenser is to increase the efficiency of induction, and it should be made in proportion to the size of the induction-coil with which it is to be employed.

Circuit-Interrupters

When an induction-coil is to be employed as a shocker (and there is no vibrating armature arranged in connection with the core), a circuit-interrupter must be employed to get the effect of the pulsations, as given out by the secondary coil when a current is passing through the primary.

There are various forms of circuit-breakers that may be made for this purpose, but for really efficient service the type shown in [Fig. 21] is perhaps the best that can be devised.

This interrupter consists of a metal cog-wheel with saw-teeth, a pinion or axle, and a handle. Also a base-block, with uprights to support it, and a piece of spring-brass wire, arranged so as to bear against the wheel. When the wheel is revolved the spring-wire will be driven out by each tooth; and when released it flies back to the wheel, striking the bevelled edge of a tooth at each trip.

Two binding-posts, arranged on the block, will provide means of connecting in-and-out wires. With a coat or two of shellac on the wood-work and black asphaltum varnish on all surfaces of the metal that are not used for contact, this circuit-interrupter will be ready for any use in connection with an induction-coil.

The base-block is of pine, white-wood, or cypress, seven-eighths of an inch thick, three inches wide, and five inches long. The uprights, which support the wheel, are half an inch thick and one inch wide. The wheel is three inches in diameter and is made of brass one-sixteenth of an inch thick. The design of the wheel should be laid out with a compass and marked with lead-pencil or a sharp-pointed awl, which will leave a mark clear enough to be seen when sawing and filing the teeth and open places.

A true plan is shown at [Fig. 21] A. Through the middle of the wheel a small hole is bored to receive the axle of brass which is to be soldered in place. When the wheel is set up, a metal crank and wooden handle should be soldered fast to one end of the axle. A piece of spring-brass wire is fastened to the block, with a staple, and the lower end bent so that the screw in one binding-post will hold it in place. The upper end of the wire is bent in the form of an L. From the other binding-post, through the block and up one support, a wire is passed, the end of which comes into contact with the axle. The current, passing in through one binding-post, is carried through this wire to the axle, then to the wheel, and so on out through the spring-wire and remaining binding-post. When in action the circuit is constantly being broken, as the spring-wire jumps from the end of one tooth back to the face of the next tooth. The pulsations are increased or diminished by the fast or slow speed of the wheel, as regulated by the hand motion. The strength of the current is regulated by the force of the battery and should be controlled by a water resistance, as described for the medical battery, or shocking-coil.

The interrupter, shown in [Fig. 22], is built up on a block six inches square and seven-eighths of an inch thick.

A circle is cut from sheet-lead and laid on the face of the block, through which pins, or steel-wire nails, are driven. The lead circle is five inches in diameter and half an inch in width, making the inside diameter four inches.

The pins or nails are driven a quarter of an inch apart, and should be properly and accurately separated, so that an even make-and-break will be the result.

It is not necessary to bore holes in the lead, but the pins or nails should be driven clear through it, so that perfect contact can be had by the metal parts coming together. Otherwise the apparatus would be useless.

Over the circle of pins a brass bridge is erected, so that the cross-strips will clear the heads of the pins. A hole is bored at the middle of the bridge so that the revolving axle will pass through it.

The axle is made from a piece of stout wire, or light rod, and near the foot of it, and about half an inch above the base-board, a disk of metal is soldered fast. A piece of spring-brass wire is attached to this disk, so that when the axle is turned the end of the wire trips from pin to pin, thus making and breaking the circuit. The upper part of the axle is bent and provided with a small wooden or porcelain knob.

One wire from the secondary coil is caught under a screw that holds one end of the brass bridge to the base; and the other to a screw, which may be placed at one corner of the block, and from which a short wire leads to the lead ring. Binding-posts may be arranged to serve the same purpose, and, of course, they are much better than the screws, because they can be easily operated by the fingers and do not require a screw-driver every time the interrupter is placed in series with an induction-coil. An interrupter on this same order may be made from a straight strip of lead with the pins driven through the middle of it. One wire from the secondary coil is made fast to the lead plate, and the end of the other wire is passed along the pins, thus making and breaking the circuit in a primitive manner.

Chapter V
ANNUNCIATORS AND BELLS

A Drum Sounder

A unique electric sounder that is sure to attract attention is in the shape of an electric-bell apparatus, with a drum sounder in place of a bell, or knockerless buzzer. [Fig. 1].

The outfit is mounted on a block four inches and a half wide and seven inches long. The cores and yoke are made as described for the [electric buzzer] ([chapter iv.]) and are wound with No. 22 cotton-insulated wire. The magnet is then strapped fast to the block by means of a hard-wood plate having a screw passed down through it; and between the coils and into the block an armature is made and mounted on a metal plate, which in turn is screwed to the block. Another block, with a contact-point, is arranged to interrupt the armature, and the series is connected as shown in the drawing [Fig. 1].