I started by taking one of the transformers apart to investigate and unfortunately the center is filled in with hard plastic so I had to drill / chisel it away to begin unwinding the original 208V primary winding. This winding was 1 in hand 2.76mm wire would approx 208 times with a splice around the middle.
So here is where I'm at since I want a split phase transformer is it just easier to leave both transformers with their intact 120v secondary winding and just wind a new primary on them?
If so can I still stack them for space reason?
Secondly the PJ is a 24V unit so is it better to wind them both as 24V primaries and connect them parallel to the PJ board or is better to wind as 48V primary transformers and connect the primaries in series to the PJ boards. The advantage of this option I can see if I ever try and upgrade to 48V the transformers would be ready. I would assume this is "easier" on the FETS as it doesn't appear as close to dead short as oppose to paralleling them.
Lastly the wire size I need to use I get a little confused calculating it, when 118V is applied to the secondary I get exactly 1.01V per turn, which if I use the 24V winding I should have 14 - 15 turns and if 48V about 30 turns? If wound for 24V would 0AWG / 8.25mm wire be correct and if for 48v 4AWG / 5 mm wire be correct?
If I leave the secondary winding alone I have approx 93mm in diameter for the open hole to fit wires so not sure if 15 turns of large welding cable will fit??
Thanks for any advise good or bad!