DIY Homemade DC Welder

[SirJakesus]

This is really cool. Thanks for the thread. I'll have to try it sometime just to make my family sh*t bricks.

 

[graucho]

Yes, interesting link. Looks very possible.
Since having things go "BOOM" in the shop plenty of times the battery welder would kind of scare me.
I think id have to have the battery configuration outside around the corner of the shop. Then have
long enough leads so the acid impact wouldn't spray me.

I do have the diagram's "series" etched into my mind though, if I ever had to get out of a jam. Thanks.

 

[Flapdoodle]

MacGyver did it with a nickle and a 12 volt battery to weld a crack in an engine block. That was the last time I watched it.

Seriously though, I suggest NOT wearing shorts as those two guys are doing on the link.

 

[srdavo]

I saw that episode ... it was a nickel! He's THE Man!! hahaha

I'm trying to find the "old time" plans for a home-made stick welder. start with a pushmower...spinning an alternator... hooked to a 12v battery...lead & grd cables. sorta like this.... but smaller. http://www.mp3car.com/vbulletin/off-topic/68235-my-home-made-welder-few-questions.html

here's another http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/

have y'all seen these mig welders? (store bought) http://www.readywelder.com/index.php

 

[ZnsaneRyder]

The guy at mp3car can't get it to work right yet. He's paralleling them for high amps, and getting only 12V. The alternators are by themselves. If he ran them in series for 24V & used batteries with them, it would work. I honestly don't think alternators have enough power alone, but if they are recharging a couple batteries, they are VERY beneficial. I'm using a battery charger, to do that, and it does not have near the power of an alternator, but works great.

Also the instructables about the microwave transformer welder was awesome! I gotta try that! I will be searching high and low now for broken microwaves! ROFL!

 

[ibdennyak]

The guy at mp3car can't get it to work right yet. He's paralleling them for high amps, and getting only 12V. The alternators are by themselves. If he ran them in series for 24V & used batteries with them, it would work. I honestly don't think alternators have enough power alone, but if they are recharging a couple batteries, they are VERY beneficial. I'm using a battery charger, to do that, and it does not have near the power of an alternator, but works great.

Also the instructables about the microwave transformer welder was awesome! I gotta try that! I will be searching high and low now for broken microwaves! ROFL![/QUOTE

Actually an alternator can produce more voltage. I built a welder using an alternator with the voltage regulator disabled. Alternators are phenominal creations....they can priduce full voltage and current at the same time, at least if they have aduquate cooling. Takes a minimum of 6-7 hp to turn it fast enough though. 10-12 is more practical. The old GM 10 or 12 S1 alternators are the easiest candidates. There is a hole in the back that if you push in a paper clip it grounds the regulator and you control the voltage by rpm. about 4-5000 rpm at the alternator will get you going usually. Right now I am working on an alternator powered AC tig welder for aluminum by taking the power off before it runs through the diodes. Then I will be able to TIG aluminum. Diodes are usually the weak point for the alternator welders....not enough inverse voltage capacity. The newer alternators even use this as a protection system....too much voltage or current and the diodes let the smoke out disabling it. I think Mother Earth News had an article on an alternator welder years ago....trying to find it if anyone is interested.

Denny

 

[DetonatorTuning]

i have the full M.E.N collection from issue #1 on, to the time the they quit and were sold. none of the new back yard yuppy junk issues.

i'll find the welder article and try to post it.

steve

 

[skyl4rk]

How long can you weld with a two battery system? Can you do a couple inches of weld before recharging? That would work out since a lot of times you have to stop and let the part cool off.

 

[ZnsaneRyder]

How long can you weld with a two battery system? Can you do a couple inches of weld before recharging? That would work out since a lot of times you have to stop and let the part cool off.

A few inches works for sure. The voltage sags under load, but it comes right back up when you stop the arc. I had the battery charger connected to one of the batteries while it was welding, to replenish between the breaks, then I'd switch to the other battery and repeat. I may mod the charger for 24V of charging, so it feeds both at the same time.

It really takes a while to drain down the car batteries. I didn't have to charge them for very long after I was done, I bet I didn't even drain them halfway.

 

[ZnsaneRyder]

I think Mother Earth News had an article on an alternator welder years ago....trying to find it if anyone is interested.

Denny

I'm sure we're all very interested. Hope you find it!