Tom,
Why not get a number of different tubes 8,6,4 ,2 inches and build multi layer with a good space between layers. I bet that would work. Steve wound his with layers of wax paper between layers to keep them smaller.
Hmmmm... now that's a very interesting idea, Frank! Steve saw problems with the thin wax paper spacing, but maybe with a BIG 1" space between runs it would work. [or maybe even 2" spacing.... 4", 8" and 12" tubes. The form factor will go to hell though. It will be a diameter to length ratio of like, 10:1 ++, instead of a nice 2:1 or less for higher Q. But maybe the pulses won't mind like an RF tank circuit would.
Do you wind the turns in the same direction each time, ie, run a lead back to the beginning and start again, or does it matter?
I also wonder how the coils affect each other to reduce or increase the total inductance. Though, I'll probably simply resonate the completed coil with a cap to determine it's final inductance anyway.
OK on the current ratings of the wire sizes. Well, looks like I better stay wid #22 insulated wire to have a decent safety factor.
BTW, I was reading about construction of big Tesla coil and these guys coat the enamel wire of the completed coil with many coats of Polyurethene. They coat until the surface is smooth and flat. I wonder if this may be a good idea to keep the turns in place from the tug and pulls of chaotic operation ?
T