Taken the cover off today to measure the wire diameter and took some pictures while I was at it.
The wire measures approx 0.71mm which is SWG22 (UK) or AWG21 (RoW) Bearing in mind although these may seem small and look odd to those familiar with Variacs in 110V countries, this winding will be a significantly smaller gauge for 220/240V countries.
I'm trying to locate a decent Type G panel mount mains socket to fit that will replace the "Multi socket" as I really do not like this.
Then need to work out what size fuse/breaker to fit on to the output. Hopefully I can get some help on here regarding current rating with the information I have so far on it. I haven't measured the brush size yet but it seems to cover 2 of the windings at any given time.
While I'm in there I'm going to add some insulated banana sockets on the front panel so I can easily put one of my multimeters on it to look at actual output voltage on&off load.
I'm also tempted to put a pair of banana sockets on the output so I can use an external ammeter/multimeter to monitor current, I can make up a pluggable link to defeat that if I don't wish to have it going through an ammeter.
I've put a bit of green tape at the top where it's exactly 1:1 so I can easily see that when adjusting it, I also scraped back some of the powder coat and bolted the earth terminal to the chassis, I'm going to add another earth terminal to the front panel to that point on the chassis and fit some star washers to all the screws. OCD made me scrub out the incorrect voltage rating on the top plate and write 240V there with a Sharpie and cover that with some clear adhesive vinyl (It had a 110V Plate fitted
)
A lot of things I repair are quite old and I buy lots of "Parts not working" items and repair them. And had quite a few things here that are "New Old stock" which have been sat for maybe 30+ years unused. Also when I design something I like to bring it up slowly to save blowing the arse out of expensive components. So this should be quite handy in the workshop as a companion to my "Lamp current limiter".
I spotted quite a few "Halogen" lamps in my local bargain store today, so hoarded a few of those in different wattages for my lamp limiter, as the sale of halogen lamps are going to be banned soon (supposedly).