I wonder if perhaps it should be a "golden rule" when using rod type
formers that whatever insulating material is involved the structure should be a
tube rather than a rod. For most practical purposes tubes will be almost as
rigid as rods but will be lighter in weight and by definition less dense than
solid rods. Even better with "basket-weave" coils might be schemes which allowed
a suitable adhesive to hold the turns in place and the former rods to be
withdrawn. As a further contribution, how about the use of glass which may be
obtained from specialist suppliers. It's possible that someone whose hobby is
glassblowing and glass sculpting might be persuaded to produce bespoke formers
also.
73 de Pat g4gvw
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