disclaimer: the following design is how i would wind the traffo from your spec. you can use it at your own risk:
Core material: EI 2 in. x 4 in. stack, core rating = 2500VA
Core weight : 12 kilograms approx.
Primary Turns: 200
Primary Wire : awg. #14 single formex magnet wire, approx weight, 1.4kilograms
Primary coil : 5 layers at 40 turns per layer
Primary coil build-up : 5 x 1.63 = 8.5mm. (excluding insulating materials)
Primary coils DC. resistance: 0.57ohms or less approx.
Primary coil rating at @ 700cm/ampere = approx. 1100watts
Secondary Turns: 76
Secondary Wire : awg. #11 single formex, approx. weight, 1.1kilograms
Secondary coil : 3 layers at 27 turns per layer
Secondary Coil build-up : 3 x 2.3 = 6.9mm. (excluding insulation materials)
Secondary coil DC resistance = 0.1 ohm or less approx.
Notes:
1. the primary VA rating is way higher than primary coil rating, so that our transformer is expected to run cooler.
2. Interleaving the E and I, 1 to 1 is recommended for manimmum field radiation.
3. Total weight of built-up transformer = 14.5 kilograms approx.
4. Total buil-up of coils(primary and secondary) is about 15 mm. so 10mm is available for insulation and bobbin, perhaps a small voltage coils can be further added (there is room for extra windings) depending on how you wind the transformer.
