This portion of the project is not my strong point, so I'm not diving into the discussion just yet.

But I do have some thoughts.

Ever hear the age old "Is the glass half empty? or half full?" ... well the Engineer says "It's twice as big as it needs to be!"

So... Stan designed these bobbins, and he's a smart guy, so why would he make it bigger than it needs to be?

"You have to learn to ask the right questions"

So what happens if we ask the question "What happens when you wind the bobbins completely full" ...

Maybe the answer is simple, and you already know, or maybe it's something that was overlooked or undiscovered. But I can't help but think that if Stan designed this thing with a certain capacity then he must have experiemented with the max capacity. Otherwise he would have did the math first, then designed the bobbins exactly to size.

Maybe he did do the math first and then designed it to it's proper size and thats what we are looking at... KISS...

KISS is telling me it is this size for a reason, so I wonder, and ask, what does the math spit out when you completely FILL these bobbins with wire?