AWG AMERICAN WIRE GAUGE TABLE FOR BARE COPPER WIRE
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also see: Tap Drill Chart, also sources for tesla coil wire

Compiled by Fr. Thomas McGahee tom_mcgahee at sigmaiscom

This Table may be copied freely so long as credit is given to the author. Originally compiled for use by those building Tesla coils on the TESLA and TESLA-2 internet mailing lists.

Compiled in April 1998 based on information derived from various sources. Since there were some discrepancies between data sources, the author has chosen not to just copy the numbers found in those sources, but rather to write a program that would generate the data based on a Best Fit mathematical model. The author has checked the Diameter in mils results against the data contained in the MACHINERY'S HANDBOOK, Twenty-First Edition, 1982, published by Industrial Press Inc. All numbers shown are accurate to +/- 1 in the least significant digit position. Column headings have been repeated to make the list more readable

AWG = American Wire Gauge size from 0000 to 40
Dia-mils = Diameter in mils (1 mil = .001 inch)
TPI = Turns Per Inch [Note that this is for BARE WIRE. Insulation thickness varies]
Dia-mm = Diameter in millimeters. This was included to help when dealing with metric Coilers.
Circ-mils = Cross sectional Area in Circular Mils. ( circular mils = diameter in mils squared )
Ohms/Kft = Ohms Per 1,000 ft.
Ft/Ohm = Number of feet required for 1 Ohm of resistance
Ft/Lb = Feet Per Pound
Ohms/Lb = Ohms Per Pound
Lb/Kft = Pounds Per 1,000 feet
*AMPS = Conservative Amp Rating based on 750 circulare mils per Amp
MaxAmps = Maximum allowable current based on 500 circular mils per Amp. Do NOT exceed this rating.




ALSO SEE: WIRE SUPPLIERS, HV CABLE & DIODES

AWG   Dia-mils  TPI       Dia-mm    Circ-mils Ohms/Kft  Ft/Ohm    Ft/Lb     Ohms/Lb   Lb/Kft    *Amps     MaxAmps   AWG
0000   459.99    2.1740    11.684    211592    0.0490     20402    1.5613    0.0001    640.48    282.12    423.18   0000
000    409.63    2.4412    10.405    167800    0.0618     16180    1.9688    0.0001    507.93    223.73    335.60   000
00     364.79    2.7413    9.2657    133072    0.0779     12831    2.4826    0.0002    402.80    177.43    266.14   00

AWG   Dia-mils  TPI       Dia-mm    Circ-mils Ohms/Kft  Ft/Ohm    Ft/Lb     Ohms/Lb   Lb/Kft    *Amps     MaxAmps   AWG
 0     324.85    3.0783    8.2513    105531    0.0983     10175    3.1305    0.0003    319.44    140.71    211.06    0
 1     289.29    3.4567    7.3480     83690    0.1239    8069.5    3.9475    0.0005    253.33    111.59    167.38    1
 2     257.62    3.8817    6.5436     66369    0.1563    6399.4    4.9777    0.0008    200.90    88.492    132.74    2
 3     229.42    4.3588    5.8272     52633    0.1970    5075.0    6.2767    0.0012    159.32    70.177    105.27    3
 4     204.30    4.8947    5.1893     41740    0.2485    4024.7    7.9148    0.0020    126.35    55.653    83.480    4
 5     181.94    5.4964    4.6212     33101    0.3133    3191.7    9.9804    0.0031    100.20    44.135    66.203    5
 6     162.02    6.1721    4.1153     26251    0.3951    2531.1    12.585    0.0050    79.460    35.001    52.501    6
 7     144.28    6.9308    3.6648     20818    0.4982    2007.3    15.869    0.0079    63.014    27.757    41.635    7
 8     128.49    7.7828    3.2636     16509    0.6282    1591.8    20.011    0.0126    49.973    22.012    33.018    8
 9     114.42    8.7396    2.9063     13092    0.7921    1262.4    25.233    0.0200    39.630    17.456    26.185    9

AWG   Dia-mils  TPI       Dia-mm    Circ-mils Ohms/Kft  Ft/Ohm    Ft/Lb     Ohms/Lb   Lb/Kft    *Amps     MaxAmps   AWG
10     101.90    9.8140    2.5881     10383    0.9989    1001.1    31.819    0.0318    31.428    13.844    20.765    10
11     90.741    11.020    2.3048    8233.9    1.2596    793.93    40.122    0.0505    24.924    10.978    16.468    11
12     80.807    12.375    2.0525    6529.8    1.5883    629.61    50.593    0.0804    19.765    8.7064    13.060    12
13     71.961    13.896    1.8278    5178.3    2.0028    499.31    63.797    0.1278    15.675    6.9045    10.357    13
14     64.083    15.605    1.6277    4106.6    2.5255    395.97    80.447    0.2031    12.431    5.4755    8.2132    14
15     57.067    17.523    1.4495    3256.7    3.1845    314.02    101.44    0.3230    9.8579    4.3423    6.5134    15
16     50.820    19.677    1.2908    2582.7    4.0156    249.03    127.91    0.5136    7.8177    3.4436    5.1654    16
17     45.257    22.096    1.1495    2048.2    5.0636    197.49    161.30    0.8167    6.1997    2.7309    4.0963    17
18     40.302    24.813    1.0237    1624.3    6.3851    156.62    203.39    1.2986    4.9166    2.1657    3.2485    18
19     35.890    27.863    0.9116    1288.1    8.0514    124.20    256.47    2.0648    3.8991    1.7175    2.5762    19


AWG   Dia-mils  TPI       Dia-mm    Circ-mils Ohms/Kft  Ft/Ohm    Ft/Lb     Ohms/Lb   Lb/Kft    *Amps     MaxAmps   AWG
20     31.961    31.288    0.8118    1021.5    10.153    98.496    323.41    3.2832    3.0921    1.3620    2.0430    20
21     28.462    35.134    0.7229    810.10    12.802    78.111    407.81    5.2205    2.4521    1.0801    1.6202    21
22     25.346    39.453    0.6438    642.44    16.143    61.945    514.23    8.3009    1.9446    0.8566    1.2849    22
23     22.572    44.304    0.5733    509.48    20.356    49.125    648.44    13.199    1.5422    0.6793    1.0190    23  
24    20.101    49.750    0.5106    404.03    25.669    38.958     817.66    20.987    1.2230    0.5387    0.8081    24
25     17.900    55.866    0.4547    320.41    32.368    30.895    1031.1    33.371    0.9699    0.4272    0.6408    25
26     15.940    62.733    0.4049    254.10    40.815    24.501    1300.1    53.061    0.7692    0.3388    0.5082    26
27     14.195    70.445    0.3606    201.51    51.467    19.430    1639.4    84.371    0.6100    0.2687    0.4030    27
28     12.641    79.105    0.3211    159.80    64.898    15.409    2067.3    134.15    0.4837    0.2131    0.3196    28
29     11.257    88.830    0.2859    126.73    81.835    12.220    2606.8    213.31    0.3836    0.1690    0.2535    29

AWG   Dia-mils  TPI       Dia-mm    Circ-mils Ohms/Kft  Ft/Ohm    Ft/Lb     Ohms/Lb   Lb/Kft    *Amps     MaxAmps   AWG
30     10.025    99.750    0.2546    100.50    103.19    9.6906    3287.1    339.18    0.3042    0.1340    0.2010    30
31     8.9276    112.01    0.2268    79.702    130.12    7.6850    4145.0    539.32    0.2413    0.1063    0.1594    31
32     7.9503    125.78    0.2019    63.207    164.08    6.0945    5226.7    857.55    0.1913    0.0843    0.1264    32
33     7.0799    141.24    0.1798    50.125    206.90    4.8332    6590.8    1363.6    0.1517    0.0668    0.1003    33
34     6.3048    158.61    0.1601    39.751    260.90    3.8329    8310.8    2168.1    0.1203    0.0530    0.0795    34
35     5.6146    178.11    0.1426    31.524    328.99    3.0396     10480    3447.5    0.0954    0.0420    0.0630    35
36     5.0000    200.00    0.1270    25.000    414.85    2.4105     13215    5481.7    0.0757    0.0333    0.0500    36
37     4.4526    224.59    0.1131    19.826    523.11    1.9116     16663    8716.2    0.0600    0.0264    0.0397    37
38     3.9652    252.20    0.1007    15.723    659.63    1.5160     21012     13859    0.0476    0.0210    0.0314    38
39     3.5311    283.20    0.0897    12.469    831.78    1.2022     26496     22037    0.0377    0.0166    0.0249    39 

AWG   Dia-mils  TPI       Dia-mm    Circ-mils Ohms/Kft  Ft/Ohm    Ft/Lb     Ohms/Lb   Lb/Kft    *Amps     MaxAmps   AWG 
40     3.1445  318.01      0.0799    9.610    1048.9    0.9534     33410     35040    0.0299    0.0132    0.0198     40
41     2.800               0.07112   7.840    1323                 40486     53563    0.0247                         41
42     2.500               0.06350   6.250    1659                 51387     85252    0.0195                         42
43     2.200               0.05588   4.840    2143                 64599    138437    0.0155                         43
44     2.000               0.05080   4.000    2593                 81103    210300    0.0123                         44
45     1.761               0.04474   3.101    3348                103627    346943    0.0097                         45
46     1.568               0.03983   2.459    4207                130378    548501    0.0077                         46
47     1.397               0.03548   1.952    5291                162602    860325    0.0062                         47
48     1.244               0.03160   1.548    6745                205339   1385010    0.0049                         48
49     1.108               0.02814   1.228    8417                258000   2200000    0.0039                         49
50     0.986               0.02505   0.973   10580                312000   3400000    0.0031                         50
------------------------

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From richard.quick at slug org Sat Sep 2 13:01:29 1995
Date: Mon, 28 Aug 1995 22:24:22 -0600
From: Richard Quick
Reply to: usa-tesla@usa.net
To: billbeskimo.com
Subject: AWG Wire Chart

      DC OHMS   WIRE    APPX TPI   FT PER
AWG  PER 1000' DIA IN.   ENAMEL    POUND
                        COVERED
 1    .1264    .2893       X       3.947
 2    .1593    .2576       X       4.977
 3    .2009    .2294       X       6.276
 4    .2533    .2043       X       7.914
 5    .3195    .1819       X       9.980
 6    .4028    .1620       X      12.58
 7    .5080    .1443       X      15.87
 8    .6405    .1286      7.6     20.01
 9    .8077    .1144      8.6     25.23
 10   1.018    .1019      9.6     31.82
 11   1.284    .0907      10.7    40.12
 12   1.619    .0808      12.0    50.59
 13   2.042    .0720      13.5    63.80
 14   2.524    .0641      15      80.44
 15   3.181    .0571      16.8   101.40
 16   4.018    .0508      18.9   127.90
 17   5.054    .0453      21.2   161.3
 18   6.386    .0403      23.6   203.4
 19   8.046    .0359      26.4   256.5
 20   10.13    .0320      29.4   323.4
 21   12.77    .0285      33.1   407.8
 22   16.20    .0253      37.0   514.2
 23   20.30    .0226      41.3   648.4
 24   25.67    .0201      46.3   817.7
 25   32.37    .0179      51.7   1031
 26   41.02    .0159      58.0   1300
 27   51.44    .0142      64.9   1639
 28   65.31    .0126      72.7   2067
 29   81.21    .0113      81.6   2607
 30   103.7    .0100      90.5   3287
 31   130.9    .0089      101    4145
 32   162.0    .0080      113    5227
 33   205.7    .0071      127    6591
 34   261.3    .0063      143    8310
 35   330.7    .0056      158   10480
 36   414.8    .0050      175   13210
 37   512.1    .0045      198   16660
 38   648.2    .0040      224   21010
 39   846.6    .0036      248   26500
 40   1079     .0031      282   33410
 41   1323     .0028
 42   1659     .0025
 43   2143     .0022
 44   2593     .0020
 45   3348     .00176
 46   4207     .00157
 47   5291     .00140

For winding Tesla secondary coils the general consensus is to use number 22 AWG, or larger diameter, double Formvar Magnet wire. Often surplus partial spools of odd wire sizes are found, so I took time to post a more complete chart of AWG numbers and fractional diameters than is usually available. All information above is approximate despite the decimal places. Wire diameter, turns per inch, resistance, feet per pound, etc. all vary slightly from one manufacturer to another. Insulation thicknesses will vary depending upon type and the supplier. Turns per inch will also vary with the quality of the winding. In practice, Tesla coil windings are not perfect (nor do they need to be) so expect some slight variations from the specification table above.

Richard Quick

.. If all else fails... Throw another megavolt across it!
___ Blue Wave/QWK v2.12

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AWG AMERICAN WIRE GAUGE TABLE FOR BARE COPPER WIRE Scroll down to wire table

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