Centrifugal air separator coil manufacturing methods

A method for forming a centrifugal air separator, the method comprising:

• selecting a thin wall metal tube with a wall integrity, an outside tube diameter, a wall thickness that is less than 15% of the outside tube diameter, a tube entrance port, and a tube exit port;
• bending the thin wall metal tube to form a tightly-coiled helical duct so that an outside duct diameter of the tightly-coiled helical duct is less than four times the outside tube diameter and so that the wall integrity of the thin wall metal tube is maintained;
• forming a duct waste port in the tightly-coiled helical duct by forming an aperture through a wall of the tightly-coiled helical duct proximate to an end of a coil section of the tightly-coiled helical duct;
• and
• enclosing the tightly-coiled helical duct in a sheath, wherein the sheath comprises a separator entrance port, a separator exit port, and a separator waste port, and wherein the enclosing comprises coupling the tube entrance port to the separator entrance port and coupling the tube exit port to the separator exit port and results in the aperture being enclosed within the sheath and fluidically coupled to the separator waste port.