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Back to the content 'got bored and built a welder from scrap parts'
this is fine and dandy, but what are the parts and design? Show me the materials list and plan so I can recreate one.
I got tons of ammo boxes but no welders.
No. It's not worth it. It isn't. I work with welders for a living. I've seen people almost killed by professionally made ones. I've been shocked twice by professionally made welders. It's not worth the risk in any way shape or form. Please don't do this.
the reason people get hurt by machines is because they didn't follow protocol, i have never been hurt by a welder in my 20 years of welding, closest i have gotten is a shock from plugs on houses when younger.
if you mess with electricity make sure you use all the failsafes and proper protective gear, this includes welding helmet for testing, gloves and a face shield and thick non flammable clothing, not to mention a voltmeter to avoid shorts.
side note, aside building this i also have installed many power plugs of varying sizes and built many other machines.
bout the only time i get hurt is when i'm making my damascus and gemstone knives, mostly because i cut or burn myself, honestly torches are more dangerous than welders, especially acetylene.
this will help you and your friends.
Both times were EXTREMELY minor shocks by TIG welders after a long day of welding. TIG isn't very absentminded compared to stick and requires a lot of thinking, at the very least for me. I slipped and tried to split an electrode in half using the arc of the tig while the copper wasn't on the table. TIG welder decided, that despite my gloves and shirt, that it REALLY wanted to get that electrode, and gave me a very light zap in my arm. Other time Was basically the same thing except that I could have, and still do, swear that that damn piece of metal was grounded, but the electricity took my arm as the shortest path. Again, very minor.
I wear full clothes, TIG gloves, everything OSHA likes. Most of my close calls came in my first year of TIG and by me watching others first year or TIG. Those days are well behind me now.
However, if a person makes their own welder, they are, despite how many videos they may watch about safety, ignorant about some things. I had a teacher. Best thing I ever did. Taught me things like "A before O or up you go", a checklist for making sure it's safe to weld, all these things.
It's nice to meet a fellow welder on FJ.
do you weld for a living, perhaps?
I do agree to your last point. Torches are more dangerous, but welders, just like lathes, straight up kill. With a torch or a bandsaw you live to learn from your fuck up. A lathe straight up breaks your neck or shatters limbs and a welder can kill you before you know what gotcha.
Grim safety reminders aside, gemstone knives? What? Can I get a picture?
side note, looks like fj keeps logging me off...-_-
damn, a gemstone knife sounded a lot cooler in my head
i was thinking like
you know what i was thinking actually
oh it's pretty damn nice, that stone is like opal under sunlight, the one i need to finish will be obsidian and turritella on raindrop damascus, the solid stone gives very good cutting feedback.
rhinestone style or facet gem mounted knives aren't comfortable and usually ugly as sin.
and yep, i strictly build for utility first.
well the above machine is basically a tig, spool gun and stick all in one, i made it modular so that you could attach any parts you like, even unplugged the caps still hold a charge that could hurt you and on a basic tig or mig there's always some extra charge left over which is why i ground it out after letting go.
split the electrode? i'd just use a dremel cutting bit then bench grinder to sharpen it, always get some really nice clean welds too(despite what people say about getting the electrodes dirty).
ye, i had 3 years of metallurgy and metal shop training at school, a magnetic checklist stamped to the side of the welder for before and after use is nice, especially when you have people who may not know anything messing around near the stuff.
the only way to get good is to learn and train and research, hell that's why i can do so many things, also watching accident videos a lot when you find them for learning is also valuable.
ye, not just a welder either, also jeweler, engineer, repairman and more crazy shit, also a gunsmith in training.
i weld to create, sometimes i get paid for creations but is rare since i prefer to do trades, i have a strong innate need to make things and stay busy etc.
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this was my last finished project aside my custom aceteline turbotorch holster.
actually torches can leak filling a room with gas, they can also explode, you plus everyone around you may not survive a torch fuckup.
>cable damascus with a labradorite crystal handle perfectly balanced at the hilt, took 3 days to make.
>simplified diagram minus regulators and extras
indicators used for the back of the unit.
the transformers are 1000w microwave parts, you cut the welds out and take them apart saving the 120v coils but removing the finer ones, do this with a soft wood block and a mallet in a vice carefully to prevent damage to windings, put the 120v coil back in as tightly as possible and on top of that wrap exactly 25' of 10# insulated wire leaving one side about 2' longer so you can route it later as shown above, use a phillips screwdriver to help make room as the windings get tight in the unit and once done clamp the thing together and weld it shut.
choice of welder caps, i don't know which is best just yet need to ask a company.
here's the welder rectifier i used
here's the regulators i plan to test soon since my main unit failed to work properly, i can't find the smaller one i used so you'll have to improvise or not use it if you only want a welder.
spool gun power transformer that goes with that as well as the rectifier to make it 48vdc to run the motor, the heatsink i mounted it to was from an old machine and i just modified it to work with a file
here's the super diodes i used, to bridge them use a chunk of 1/4" copper tubing flattened on one side with holes drilled to fit those studs, the heatsink was made from a chunk of thick rectangular aluminum tubing i cut with a saw and drilled to meet my needs, there's a hole in the back to pull air inside as well as a large o-ring and chunk of metal screen that was clamped in behind to hold it in, there's 2 holes the same size on the oposite side of the welder so that more air can be pulled in for the rest of the parts to keep cooled, also has a metal screen and they were placed beh=ind the flaps to open the lid to hide them better.
you'll need this to crimp your terminals.
the power plug is 600v extension cord and one of those metal water tight cord fittings with a 220v plug from the hardware store(a 220v plug tapped from the middle to the sides one at a time is 120v advise a multimeter to help you clear any errors)
fuse i used
you can get the shrink wrap and copper terminals at the hardware/automotive store or off ebay same goes for the welder clamps and cables
cables and connectors you'll need.
also advise a large step down drill bit to make your holes plus a small file for the notches to prevent twisting, i have not decided on a plug type for the spool gun extras yet.
this fan should work.
insulator/sorter that will work for cleaning up the wires etc, all fasteners are domed torque head screws with nylon lock nuts and pop rivets in 1/4" and the cable bar is just flat stock aluminum bent in a vice
, corrected diagram
also here's the ammo can
Back to the content 'got bored and built a welder from scrap parts'
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