Transformer people use rules of thumb like 500 circular mils/amp. This takes into account the fact that the inside of a transformer will get warmer than a wire in open air. I think a reasonable estimate for your purposes would be something like 200 cir mils/amp. For example, 30 gauge wire has a diameter of 10 mils giving an area of 100 circular mils. The above rule says you should be able to pass half an amp and not melt the wire. It takes MUCH more current than 500mA to melt a piece of 30g wire-wrap wire. I just used my bencchtop supply to run 3A through a piece and it didn't even glow or discolor due to heating. That doesn't mean the rule of thumb is invalid, though. I'd expect the first concern to be "excessive heating", just due to system issues. (and there's a LOT of wire in a transformer, so even a little bit of heat/cm will amount up. Secondly, you'd run into "don't melt the insulation", followed by "don't melt the solder", with actual wire-melting WAY up there on the list of concerns. BillW