Dave
How a pickup works
Basically a guitars pickups works on the same principle's as an electric generator,
Coil + magnet + motion = electricity
A vibrating steel (or other ferro-magnetic metal) string causes a flux in the magnetic field created by a pickup's coil, a flux that produces an alternating (AC) voltage (a signal)
More info
http://www.guitarnuts.com/wiring/pickups.php" onclick="window.open(this.href);return false;
http://buildyourguitar.com/resources/lemme/" onclick="window.open(this.href);return false;
http://www.guitar-repairs.co.uk/how_gui ... s_work.htm" onclick="window.open(this.href);return false;
Pickup anatomy
Winder
To wind a pickup you are going to need a winder, there are too many turns making it far too time consuming to wind by hand. There are many types of winders pickup maker’s use and most are built by the maker.
Simple and popular with hobbyists is a hand or electric drill 1 2 or a winder using a sewing machine motor. While winders can be much more complicated being fully automated and programmable.
A schatten pickup winder can be bought from Stewmac.
This is my winding set up. I used the table height and depth stop to control the winds; the felt lined clamp was used to guide and to tension the wire. The setup still needs some work. I am currently designing a standalone winder.
Counter
It is necessary to be able to count the winds for repeatability. this site explains how to make a simple counter out of a calculator. Counters can also be made using a electronic counter 2 and a reed switch or hall effect sensor. (Note: I now use a standalone counter built from a kit)
This also shows you how to make counter with their program, a reed switch and a serial port cable.
Parts
Finding parts for winding pickups can be difficult. For hobbyists supplies can be sourced from Stewmac, Guitar Jones, Guitar parts USA, Allparts and AMPGE
Strat style pickup
Now we will go through winding a simple strat pickup, Below are the parts needed.
I used 8000 turns of 42 AWG wire and Alnico 5 magnets.
I magnetized the pickup using the same method as option 2 here http://www.stewmac.com/freeinfo/I-5967.html" onclick="window.open(this.href);return false;
Potting
This is my potting setup.
I used a mix of 80% paraffin wax (I used surfboard wax because I had it on hand, it's just paraffin with a few additives) and 20% beeswax. The beeswax mostly stops the paraffin from expanding and contracting with temperature changes and lowers the melting point of the mix.
I used a slow cooker (NEVER use a microwave or open flame) and a tuna can to melt the wax, use a deep fryer thermometer to monitor temperature (140-150 F, 65 C is good, don't let it get much hotter as you can damage bobbins, also paraffin vapor is pretty flammable)
Place the pickup in the wax for about 10-15 minutes; tap the pickup on the base of the container to help any air escape. Remove pickup when bubbles stop coming out and wipe off excess wax off with paper towel.
Finished pickup
Useful Sites/Further reading
http://www.ampge.com/
http://music-electronics-forum.com/foru ... y.php?f=11" onclick="window.open(this.href);return false;
http://galileo.spaceports.com/~fishbake/
http://designed2wind.alphalink.com.au/
http://www.harmony-central.com/Guitar/e ... uction.txt" onclick="window.open(this.href);return false;
http://members.lycos.nl/ajgp/pickups.html
http://users.chariot.net.au/~gmarts/pickups.htm
http://europa.spaceports.com/~fishbake/buck/humbuck.htm
http://pickups.myonlinesite.com/programs.php
http://www.diyhappy.com/how-to-make-a-g ... ss-pickup/
http://www.robkidd.homestead.com/PickupWinding.html
http://skguitar.com/
http://home.zonnet.nl/wilmaremy/makingpups.html
