New coils

[chesty]

I haven't looked at a factory coil in detail, but the rebuilds are built using a single piece of wire all the same gauge.
the wire only heats up in the spots where it isn't touching the metal case or pin, in theory. so it shouldn't burn the grommet, in theory.
in practice it can and does.

-------------------------
-------------------------x-----------------------------------
---------------------

If you image that;s a cross section of a part of a head, the top line being the metal sleeve, the middle long line being the leg of the coil and and bottom line being the insulating grommet, the heating coil circuit starts at x where the leg of the coil stops touching the metal sleeve.

of course the wire conducts heat, and the leg of the coil isn't soldered onto the sleeve, but in the perfect world, the legs would only get hot after the grommet.

once again, this is just my current thinking based on electronics I did 20 years ago.

 

[BigBen2k]

I understood that these types of coils, because they have long legs, use a thicker wire that's spot welded, right after the coil. I've seen this in other's posted pictures here, but I haven't ripped a T2 coil apart yet.