The first three pictures show the first spark gap design, created for use in a 4" Tesla Coil running 1kVA. The gap runs ice cold with intermittent coil operation, and warms up nicely with sustained full input power.

Specs:

• Six electrode holders, five gaps
• Electrode holders are 1" diameter, 1.5" tall, alloy 360 brass "rounds".
• Electrodes are 3/32" tungsten
• Gap spacing is adjustable from zero to 3/4"
• Baseplate is 0.5" x 3.0" x 12" grade G3 fiberglass bar
• Legs are made of 1/2" HDPE blocks fastened to the baseplate with nylon hardware

The second row of pictures show a bigger spark gap design, created for a new 4" Tesla Coil running 2.5kVA. This guy runs ice cold, always, and does not experience quenching problems even at high power levels (tested up to 4kVA).

Spec's:

• Six electrode holders, five gaps
• Electrode holders were cut frome 1.5", alloy 360 brass square stock.
• Electrodes are 3/32 tungsten
• Gap spacing is adjustable from zero to 1"
• Electrode holders are bolted to 3/16" x 3.0" x 14" grade G10 fiberglass bar
• Unit stands on small ceramic insulators, mounted with nylon hardware

Materials for both spark gaps were purchased online from McMaster-Carr supply company. Estimated cost for the smaller spark gap is $40.00, cost for the larger one is $60.00.

Both me (Justin) and Aron made these gaps, in Aron's workshop using his tools. It took a chop saw (to cut the brass), belt sander (to clean up and get exact), tablesaw (to cut the baseplates to size), and drill press (obviously) to create these things!!! It took both of us about 4 hours to make the small red gap, and about 6 hours for the bigger one.

So far it has been worth making them. They look ok, are low maintainance, highly adjustable, and perform flawlessly. Both gaps have been tested at up to 4kVA and do a great job as far as quenching goes. Always a loud raspy, crackling sound, like a jackhammer compared to frying bacon. Okay, maybe not a good comparison.

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