How do you make a factory resistor?

DIY Wire-Wound Resistor Coating

The wire-wound resistor from the 60s or 70s originally had an off-white ceramic or plaster coating. This specific coating is critical as it needs to withstand high temperatures.

One modern solution I came across is Cerama-Dip. However, the smallest jar costs over $100. Another suggestion was using sodium silicate, which can also endure high heat levels.

Your recommendations on suitable, high-temp-resistant coating materials would be greatly appreciated, especially since the resistors heat up significantly during use.

Recently, I had to remake a wire-wound resistor for an old Sunbeam mixer. Based on my research, it appears that 36 AWG nichrome 60 wire wrapped around a ceramic core is the standard. The challenge remains to find an effective coating material. Although I have a picture of the previously used brown coating, the original rebuilder is no longer available to consult.

For more information, do consult a resistor manufacturing factory. They can offer professional advice and provide adequate solutions.

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