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  #1  
Old 07-26-2021, 02:45 PM
Dan(NM) Dan(NM) is offline
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Default Excal coil replacement.

I just got my bargain Excalibur in today, everything looks good but the coil cable is shot. Any suggestions on what my options are will be greatly appreciated. Minelab wants $168 for the coil plus an hour of labor and of course they want to go through the rest of the machine.
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  #2  
Old 07-26-2021, 07:28 PM
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Over the years I repaired a few, early on there was no need to repair..10 years ago, but Now, it is impossible to get a stock coil, new or used. There is a cheap repair I can post pictures and parts list if you want to try. You will need to break the machine down and cut out the old coil wires from the endcap, then solder the new cable to the board. Not real hard but not for the weak at heart.

I posted it over on Steves forum but seems that forum has disappeared.

My opinion, it maybe best just to send it in and have them check all out.

Let me know I will do a list for you...
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Old 07-26-2021, 09:53 PM
Dan(NM) Dan(NM) is offline
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[QUOTE=OBN;3328109]Over the years I repaired a few, early on there was no need to repair..10 years ago, but Now, it is impossible to get a stock coil, new or used. There is a cheap repair I can post pictures and parts list if you want to try. You will need to break the machine down and cut out the old coil wires from the endcap, then solder the new cable to the board. Not real hard but not for the weak at heart.

I posted it over on Steves forum but seems that forum has disappeared.

My opinion, it maybe best just to send it in and have them check all out.

Let me know I will do a list for you...[/Q

Thanks Joe, when you get some spare time, can you post the parts list for the cable replacement, thank you sir!!
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Old 07-26-2021, 10:25 PM
zeemang zeemang is offline
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I have done two replacements, and I have to say honestly, if they will do it for $168 plus a bit of labor and it would have a warranty GO THAT ROUTE. Just finding a stock coil on the secondary market is a pita these days...

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  #5  
Old 07-27-2021, 12:17 PM
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Be posting several pictures the next 24 hours.
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  #6  
Old 07-27-2021, 12:27 PM
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Depending on much of the cable is bad, cutting out the bad section and use waterproof connectors to put it back together. It maybe only a matter of time before the cable cracks elsewhere before you need to repair it again.

More than likely, it has been my experience that when the outer insulation cracks water works it was further into the cable and even into the coil. I have found used coils with enough cable to replace a bad coil again by using the waterproof connectors.

It is no easy task to replace the coil by wiring it through the control tube end piece and soldering it to the main board. I have done several, but it really is not worth the couple of hours of work to accomplish the task unless you enjoy the challenge and have nothing else to do, like go detecting.
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Old 07-27-2021, 12:28 PM
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video on desoldering the board..
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Old 07-27-2021, 12:36 PM
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Fixing the endcap is similar to this.. this is the head phone side.
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Old 07-27-2021, 01:02 PM
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Epoxy used and I got a black dye for the epoxy which is only for looks. Also you can use PVC pipe for the repair tube and shape it to fit better. I used 1 inch acrylic tube, 1/16 wall inch from Amazon.

I would guess over the years I have replaced 50 plus cables, I have yet to have one fail, the cable from McMaster Carr will out last the coil itself. Total cost is around 30 dollars to repair, well worth the time and effort. Any questions just ask..

Good Luck!
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Old 07-27-2021, 01:13 PM
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Important to cut the strain relief and put the lower half back on with a small gap. Once the epoxy is poured in place this locks all in.. And you have about 5 minutes on the epoxy to fill in...Also I put the plastic sleeve on and seal the bottom first, let that dry then fill the fill all..Not sealing the bottom first can allow the big pour to leak out..Not Good.
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Old 07-27-2021, 06:47 PM
zeemang zeemang is offline
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OBN on the ball, best guide I have seen!

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  #12  
Old 07-27-2021, 07:16 PM
Dan(NM) Dan(NM) is offline
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Thanks OBN!!!! I appreciate you taking the time to post the info. I have everything but the shrink wrap, resin dye and cable. The Excal works and the inside was very clean, no signs of water intrusion. The top o-rings were toast, new 0-rings on the way. The battery seems to be fine, his charger was only charging the battery to 9.67 volts. I have a different charger that bought the battery up to 11.24 volts. I haven't tested it yet to see if it'll hold a charge under load. I have a aftermarket battery on the way as well.
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Old 09-24-2021, 02:56 AM
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Hi OBN & All. I have a similar issue with 2 excals that have cable deterioration. Could you recommend a cable replacement for the headphones?

One of my excal I purchased used already had cable insulation completely gone and I sent it in for replacement for new coil and headphones. Unfortunately after several years the cables are starting to deteriorate. My other excal purchased new lasted about 6 years before the cables deteriorated. Because of my experience with the factory cables Iím leaning toward the diy replacement described here. I wonder if the problem could be the heat and humidity here in Hawaii.
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Old 09-24-2021, 10:29 AM
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Get them off ebay, workman CB Microphone cord, I get the 6 wire, and just double up..3 / 3 or you can do single. I have yet to have one of these fail. Over the 7 years i've used these on repairs n head phone builds.

Not sure but the break down of the stock cables happen everywhere. Just keep these sprayed with 303 n I would bet they will last many years.
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  #15  
Old 09-24-2021, 10:39 AM
Bklein Bklein is offline
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Is the acrylic tube sealed to the coil with aquaseal or?
(Before the pour)
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  #16  
Old 09-24-2021, 12:19 PM
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I use the fast dry epoxy for the base seal. the 24 hour for the fill, also add a black dye. The most important thing is to make sure the heyco fitting is in perfect placement so when the 24 hour epoxy dries, all is locked into place.
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  #17  
Old 09-24-2021, 12:29 PM
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Originally Posted by OBN View post
..... The most important thing is to ...
OBN : Thanx for all the great tutorials here !
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  #18  
Old 09-24-2021, 05:18 PM
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OBN,
Thanks for the great info and pics. I think Iíll give the diy repair a shot.
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