For some reason my drawing didn't appear in an earlier reply.

I'm trying it again, with the question of how to wire it.

Continuity tests good for every lead, except for 3.

I think that is how it should test.

I've disassembled and reassembled it a couple of times now, and I believe it is ready to hook up and test.

My enclosure will be a cardboard box for now.

Thanks, Gary

 

The cardboard box is no good, too flimsy.
I found a can, slightly larger than a coffee can.
It sets inside cleanly, and I've insulated the mounting screws (looks crude).
Still temporary at this point.

 

Does this wiring diagram make sense?

 

Yes.

A good way to trace out a Variac is to give it something less dangerous, like 12 VAC or 24 VAC and measure voltage.

 

Does this wiring diagram make sense?

Looks like it is self explanatory,1-4 input for 120v volt supply?
1-3 or 4-3 output depending on whether you want increasing or decreasing supply?

Max.

 

Does this wiring diagram make sense?

Look in the Volts column.
If you want, 0 to 140 volts, then use on input/outputs in the 140 row, if you want 0-120 volts, then use the connections in the 120 row.

Normally, use the 120 volt output and connect your inputs to terminals 1 and 4. Then, the output connections will depend if you want clockwise or counterclockwise turn for increasing volts.

Then you flip your dial for 0-120 volt range.

I have found the 0-140 volt range useful for stress testing, but I tend to avoid it.

 

I think I will try the 12v or 24v approach to test it out.
If successful, I intend to tie in a volt meter and amp meter I have.

Looks promising, thanks for everyone's input.
Gary

 

I forgot to post back.
I did get it working, and it looks good too.
Perhaps I'll post pictures this weekend.
Anyway, now I have a solution, looking for a problem.

Thanks everyone for your help and input.

Fun stuff,

Gary

 

Here are a couple of photos.

I need to paint it (when the weather turns nice).

Thanks again for everyones input.

I bought a Router Speed Control at Harbor Freight for $14.00 & something.
That is a lot easier and lighter for most of my needs.

Never the less, I'm happy with how this turned out.

Gary