Transformers kind of "peaked" out during the "golden age of audio" when people were really fussing over the details.
Audiophiles had a wealth of voodoo to explore, turntables, tubes, transformers, money meant nothing to the high end nuts.
But now, everything is on a chip, so it can be small, light and cheap, and quiet and better sounding.
So the first component the engineers had their murderous eyes on was transformer.
"If we could just get rid of that....."
Well. they did. Slowly but Shirley, UTC, Peerless, Triad (although still in bizness) they went away.
And now, anybody who wants to recreate the past, will have a lot less options to work with, unless he's a millionaire and wants Mag Metals to do an old school run of lams.
So laminations is one limitation, next would be winding equipment.
Apparently, UTC had some real specialized custom made equipment for winding those A-10's.
They use foldback winding on the secondary, becuase they wind two pies at the same time. And when you switch directions to add another layer, and only one wire wants to track properly, you have a problem.
So what you do with that fine hairwire, is to bring then Both all the way back over to where you started, that way you can put a cam in the machine which will increase the pulley angle so much, that both wires have no choice but to come back over at the same time to start another layer.
So, I don't know if Magnetica inherited any of this equipment, but that is another problem you will have with the UTC stuff.
Ever wonder why nobody takes the time anymore?
It's a pain in the ass! And if the money does not justify, ...
So lams, winding machinery, what else is in our way?
Wire is not the same. The old insulation was improved upon, so now the insl to copper ratio is all different, this means that the coil build will be slightly different, which will change capacitance, and thus the resonant peak frequency of the transformer. UTC had to use interlayer insulation in order to provide enough space between layers in order to prevent breakthru.
Nobody is going to bother with 0.0005 paper anymore. How would you cut it, anyway?
You don't. You wind 24 coils side by side and cut them apart with a band saw. This way, you do not fuss with 24 strips of paper every layer, just one.
You will probably not be able to afford enough copper wire to spin 24 coils at once, so you will have to find a machine to cut 0.0005 paper accurately.
OK, lams, wire, paper, machinery, what else?
Mu cans. You will need three telescoping mu cans to get the same shielding. Maybe shielding isnt a problem nowdays?
No more AM transmitters around the studio.
Maybe we can use 1 nested can in an forged outer can for B max protection?
OK, but will that influence the sound?
Then the potting compound. Every xfmr I took apart had a different smell.
I heard that they use to dispose of chemical wastes at the factory by putting all the stuff in a big holding tank, adding some PCB's and polycrystaleine wax for good measure, and mix it up for potting compound.
Langevin had the weirderst smelling stuff. Peerless was the cleanest. Triads was some in between. UTC did not use wax. Just black tar, to hold the lams. The wires are free to vibrate at high frequencies, specially after dryout, when the 0.0005 paper becomes 0.0004 thick, providing more space to rattle, which is a form of mechanical feedback, which will effect the high end.
No wonder I am so weird, all those fumes!
So different recipes for wax means different dialectic constant means different sound..
Good idea, though. Ship all your waste out in tiny little packages, all over the world.
So big deal. Whats potting compound gonna do anyway?
Well, it gets in between the windings during vac impreg, and forms a dialectic. This changes the capacitance>res freq>sound of the transformer.
So we have lams, wire, machinery, mu cans, and potting compound.
OK, I will just go ebay and save the hassle.
Well, all that stuff inside the xfmr, all these years, and the loosed lams i see in half the utc's I pull apart, hard to say if they sound the same and won't break from high voltage, due to erosion of the insulation of the wire and paper.
So you can change winding structure, but everybody is stuck with the same alloy from MagMet, so this leaves one other option: lam shape.
There are a million lam shapes and stacks, and they influence sound.
When UTC picked a lam, they designed the hell out of it. Why?
So they only had to stock a few part numbers.
When Ersel B Harrison did something weird by using nickel for the Peerless 217 output, lord have mercy, well, he probably used that lam a lot of other places. This saves redesign time also, since you use the same insulation and tooling to build the thing.
He also used the same geometry over and over again, the 5-4 sandwich.
5 secondaries-four primaries, for the high dollar 20-20 series..
Do anymore layers, and its diminished returns due to leakage-layer build up.
So these guys were lazy. And pressed for time. So time Is on your side, since it's not your job to knock out transformers.
So experiment with different lam shapes.
Use the 5-4 layering, it don't get much better than that.
Get a MagMet catalog.
Or go online.