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Building cheap portable dc gas welder

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ken

04-29-2003 14:13:55




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hi anybody got any cheap plans and need ideas and feedback on building a cheap portable dc welder thanks alot everybody who has been helping me




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Robert Bodell

09-14-2004 08:15:30




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 Re: building cheap portable dc gas welder in reply to ken, 04-29-2003 14:13:55  
Here is one I built last year out of junk microwave oven transformers. It's ac/dc. Cost me about 25 bucks for the AC unit and about 80 bucks for 250 volt 400 amp diodes to make the dc unit. It does about 100 amps and runs off of 115 volts. I built a couple extra transformers in case I burned one up but try as I can, I haven't been able to burn one up yet. Its pretty close to 100 percent duty cycle. I put it on the trailer that holds my 6.5 KW onan generator plant so it goes anywhere. if You got the generator, a buck an amp isn't bad.

Link
Id be glad to answer questions.

www.surpluscenter.com has some 140 amp DC welding generators for 99 bucks #6-987x and 300 amp for 169 bucks #673 and reactors for 100+ amp welding generators for 35 bucks #1162. They also have some 400 amp belt driven ready to run welding generators with controls. #156-b 479 bucks and #156 399 bucks

www.Harborfreight.com has 10 KW 120/220 generator heads #45416-1VGA for 399 bucks and are on sale at the present for 299

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Taylor Lambert

05-04-2003 18:29:41




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 Re: building cheap portable dc gas welder in reply to ken, 04-29-2003 14:13:55  
Ken theres a place that sells pans to make one with a small gas motor and one with a 4cylinder one. I had a cousin that made one from a lagre dc generator from an old greyhound bus I welded with it alot. Ill drop you and emailwith the link to the welder projects.



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Tom

05-02-2003 09:02:53




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 Re: building cheap portable dc gas welder in reply to ken, 04-29-2003 14:13:55  
Be careful. You may end up with a costly, dangerous, pile of junk. Buying a good AC/DC Lincoln or Miller might be cheaper in the long run than serious injuries. Some of the solutions below are an accident waiting to happen, such as exploding batterie acid in your eyes.



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Ben in KY

05-02-2003 11:46:04




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 Re: Re: building cheap portable dc gas welder in reply to Tom, 05-02-2003 09:02:53  
Yeah Ken, I don't think I would want to weld with batteries unless it was a "have to" situation.



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jim

05-01-2003 19:27:07




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 Re: building cheap portable dc gas welder in reply to ken, 04-29-2003 14:13:55  
Lots of ideas out there, some sound kind of scary. Go to www.motherearthnews.com ; in the article archives should be an article on just what you're looking for - with pictures and detailed schematics. Lindsay Publications also has plans for homebuilt welders. I saw one of the motherearth news welders work about 20 years ago and it did work; it worked better with thin rod, but remember it was built out of junk and cost essentially nothing. good luck

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Bill 52 8n

05-01-2003 12:58:06




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 Re: building cheap portable dc gas welder in reply to ken, 04-29-2003 14:13:55  
I looked at getting one of these welders and making a portable welder....kinda. I had the idea to mount it on an old craftsman lawnmower. I was gonna take the deck off, mount the welder underneath and connect it to the pto pully, and then hang the welding cables on the back of the tractor. Then I could drive it to where i needed it, flip the lever for the blades which would turn the welder on and start welding. Then my sister's bf "loaned" me his 200 amp mig welder so i never made it.

Bill

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hay

05-01-2003 03:27:44




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 Re: building cheap portable dc gas welder in reply to ken, 04-29-2003 14:13:55  
been there, done that on trying to build my own welder. never could get the durn thing to work decently. it was even less power than one of those small 110 volt "crackerbox" welders that you can buy a wal-mart or similiar places. by the time i got everything together, i had more money in it than buying one. look in sears tool catalog and they have a portable cordless mig welder. not cheap but very portable and rechargeable.

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Ben in KY

04-30-2003 12:14:17




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 Re: building cheap portable dc gas welder in reply to ken, 04-29-2003 14:13:55  
Ken, You might want to check out surpluscenter ( add the dot com, etc ). They have welder/generator heads.



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G Taylor

04-30-2003 09:41:12




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 Re: building cheap portable dc gas welder in reply to ken, 04-29-2003 14:13:55  
The cheapest and best is to find a fairly low hours used engine powered welder/generator at bankruptcy sale. Or purchase a 7500W portable generator and a AC/DC welder. 99% of home built tinker projects cost more, take more time and don't work as well as the off the shelf item.



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Robert in W. Mi

04-30-2003 12:12:57




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 Re: Re: building cheap portable dc gas welder in reply to G Taylor, 04-30-2003 09:41:12  
Only thing cheaper would be a small gas engine, chev, alternator, and several 12v batts wired in a series. The engine will power the alt. to keep the batts charged, and all the batts in a series with a welding clamp on the end of the "end" batts, will weld!!! YES, it will work, but probably not what the origional poster wanted!! I had a gas powered welder, BUT, my gen set with my welder plugged in is a better idea and much more usefull for me! Robert

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ken

04-30-2003 12:35:32




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 Re: Re: Re: building cheap portable dc gas welder in reply to Robert in W. Mi, 04-30-2003 12:12:57  
in regards to ideas cool ideas and love all your opinions.
following up in regards to : robert in W. IN.....
DO OYU HAVE A SKETCH OR ARE YOU ABLE OT TELL ME IN DETAIL HOW YOU MADE YOUR IDEA COME TO LIFE? THANKS



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Robert in W. Mi

04-30-2003 16:22:07




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 Re: Re: Re: Re: building cheap portable dc gas welder in reply to ken, 04-30-2003 12:35:32  
Use a small gas engine with a pully on it to run a Chevy alternator. The reason for a "Chevy" alt. is because it has a built in regulator and is easiest to wire.
If you take the pos. and neg. batt cables and touch them together sparks fly, right? If you hook several batts together pos to neg to pos to neg ect.. (each batt up's the voltage 12v) and put welding cables (not too long of ones) on the last pos and neg in the chain. (use the "unused" post on the first and last batts) put the neg on the metal you want to weld, and a welding rod in the cable to the pos side of the batts, (it will work either way) and weld away. More batts will burn a bigger rod. You have to expierement to see what works.
Meanwhile the gas engine will be running and putting some amps back into the batts.
Nothing fancy, but it will work! It also can be DANGEROUS to throw sparks around batts., so be CAREFULL!!!
My best advice, BUY A WELDER!!!
Robert

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bob

05-01-2003 06:40:01




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 Re: Re: Re: Re: Re: building cheap portable dc gas welder in reply to Robert in W. Mi, 04-30-2003 16:22:07  
And just how do you wire a single 12 volt alternator to charge a series string of 12 volt batteries? I have a limited knowledge of things electrical, but wouldn't you have to have an alternator that puts out the same amount of voltage (actually slightly more) as the "series" string of batteries? In other words, 4 batteries in a series string would require about 52-54 volts to charge them. With only a 12-volt alternator the batteries would have to be wired in parallel.

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Robert in W. Mi

05-01-2003 07:09:33




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 Re: Re: Re: Re: Re: Re: building cheap portable dc gas welder in reply to bob, 05-01-2003 06:40:01  
Yes, you have to charge them one at a time. You really don't need 4 batts though. I've seen a guy weld with one batt and an alt hooked to it as described above though. Actually, i didn't think my origional post would find anyone who would want to try this, even though there are people who do weld with batts. There are several companys selling big alt kits that have welding capability built in them. Robert

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ken

05-01-2003 09:39:22




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 Re: Re: Re: Re: Re: Re: Re: building cheap portable dc gas welder in reply to Robert in W. Mi, 05-01-2003 07:09:33  
in regards to roberts idea.....i need more imput lots of detail..ideas.....sketches and ideas..
i do not fear welding at all.....4th generation welder..... certified blacksmith....
got my journymans in electical and was a mainmt mechanic for over 18 yrs so nothing scares me anymore..... ALTHOUGH 1 WRONG MOVE AND ITS POOF :)



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Robert in W. Mi

05-01-2003 14:48:41




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 Re: Re: Re: Re: Re: Re: Re: Re: building cheap portable dc gas welder in reply to ken, 05-01-2003 09:39:22  
Hey Ken, "If" you really are an, "..4th generation welder..... certified blacksmith....
got my journymans in electical and was a mainmt mechanic for over 18 yrs."

you sure don't need any help from me!!! You are way more qualified than i am, and should already know more about all this than i'll EVER know!!!

GO BUY A WELDER!

Robert



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ken

05-01-2003 16:03:52




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 Re: Re: Re: Re: Re: Re: Re: Re: Re: building cheap portable dc gas welder in reply to Robert in W. Mi, 05-01-2003 14:48:41  
regarding robert....
i still need everybodys imput..... low on funds and need to make a welder as cheap as possible.BELEVIEVE ME EXPERIENCE IS NOTHING
I GET ALOT OF IDEAS AND IMPUT FROM EVERYBODY
JUST BECUSE I KNOW A FEW THINGS
ITS NOTHING
I AM NO BETTER THEN ANYBODY ELSE
I AM PROBABLY ASTUPIDER



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Steve

05-01-2003 06:38:16




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 Re: Re: Re: Re: Re: building cheap portable dc gas welder in reply to Robert in W. Mi, 04-30-2003 16:22:07  
You're definitely right when you say it's DANGEROUS. Welding draws a lot of current which translates to the liberation of a lot of hydrogen gas from the batteries. Last time I checked, hydrogen gas is explosive. If you want to make a welder look into making a transformer. You can hook that to your generator to get the current boost you're looking for. That's all a welder is anyway.



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KEN

05-01-2003 09:42:29




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 Re: Re: Re: Re: Re: Re: building cheap portable dc gas welder in reply to Steve, 05-01-2003 06:38:16  
steve....
whats the idea of the transfomer?
give me imput and details



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steve

05-02-2003 06:14:20




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 Re: Re: Re: Re: Re: Re: Re: building cheap portable dc gas welder in reply to KEN, 05-01-2003 09:42:29  
One other note:
The transformer has to be driven by an AC source to work. Power transfer from the primary to the secondary side depends on the change in current on the primary side. This will give you an AC output on the secondary side (which gets connected to the leads for your welder).
In order to weld DC, you would have to hook up a rectifier (AC to DC converter) on the secondary side.

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steve

05-02-2003 05:41:32




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 Re: Re: Re: Re: Re: Re: Re: building cheap portable dc gas welder in reply to KEN, 05-01-2003 09:42:29  
Ken,

Electrical power is Voltage x Amperage. If you have 10 volts worth of potential and 10 amps of current, you are using 100 Watts of power. Transformers allow you to change the relationship between voltage and amperage. With a transformer, you can step the voltage down and increase current (or vise versa). Using the previous example, if you run the 10 Volt/10 Amp source to the primary side of transformer, you could achieve 5V/20A on the secondary (notice power is still the same). The ratio of Voltages achieved across the coil is dependant on the ratio of turns on each side.
Since a picture is worth a thousand words, look at the diagram on the following website:>Link
You>Link can find more information on the topic by searching for "transformer theory". I hope this helps. As always, be careful when you're playing with this stuff!! One note: make sure you use insulated wire when you make the coils. The number of turns in the coil is what determines the strength of the magnetic field. That is what transfers power between the primary and secondary loops. If you use uninsulated wire, the current will simply jump across the coils rather than going through all the wire. Welders have variable transformers that allow different current settings. If you make your own, you'll only have one setting. Also, you'll probably need a fan to cool the transformer. Remember, if your insulation melts, the coil will short and your welder will be finished.
Take it easy,
Steve

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Ben in KY

04-30-2003 10:44:10




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 Re: Re: building cheap portable dc gas welder in reply to G Taylor, 04-30-2003 09:41:12  
"99% of home built tinker projects cost more, take more time and don't work as well as the off the shelf item"

Speak for your own projects :) No offence taken by me, nor do I intend to offend. Just my opinion/observations.



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Central Minnesota

04-29-2003 19:13:55




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 Re: building cheap portable dc gas welder in reply to ken, 04-29-2003 14:13:55  
How cheap? How portable? How much current? isotrol@rea-alp.com Maybe I can help you.



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Krylon

04-30-2003 14:43:23




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 Re: Re: building cheap portable dc gas welder in reply to Central Minnesota, 04-29-2003 19:13:55  
third party image

Battery powered welder.

Link



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