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Portable welder made from generator or alternator?

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Paul

11-14-1998 23:30:03




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Has anyone made or know of plans to make a portable welder from a generator or alternator?




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Terry

11-21-1998 18:16:24




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 Re: Portable welder made from generator or alternator? in reply to Paul, 11-14-1998 23:30:03  
I made a welder out of an old jeep engine and a 100 amp 12V truck generator. Just connected the armature direct to the field, and hooked up a rod holder.

I regulated current by setting the rpm with a hand throttle. Worked Ok for light work.

I don't know if you could get a setup like this to put out serious current though. It lasted 15 years before the generator burned up.



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payne

11-15-1998 02:27:09




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 Re: Portable welder made from generator or alternator? in reply to Paul, 11-14-1998 23:30:03  

: Has anyone made or know of plans to make a portable welder from a generator or alternator?

I have seen them built from old aircraft D.C. generators.



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john d.

11-19-1998 05:25:12




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 Re: Re: Portable welder made from generator or alternator? in reply to payne, 11-15-1998 02:27:09  
: : : Has anyone made or know of plans to make a portable welder from a generator or alternator?

: I have seen them built from old aircraft D.C. generators.

Saw pictures of one once that was built on a lawnmower deck. Had a 3.5 Briggs engine belted to a 12 volt alternator which charged a BIG 12 volt battery. Welding was done with battery power, and the alternator simply re-charged it. Might work for intermittent use. The system would need some means of controlling how much amperage was available at a given time, because a dead short across the battery would provide many times the desired amount. There would also be some safety considerations with such a device, including sparks getting near the gas tank, and the potential of battery explosions due to hydrogen gas accumulation during charging. I'm not saying it's a GOOD idea, just that I saw pictures of one!

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Paul

11-20-1998 07:04:40




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 Re: Re: Re: Portable welder made from generator or alternator? in reply to john d., 11-19-1998 05:25:12  
Might work.I am really interested in driving a generator or alternator and using just the output from them.
: : : : : Has anyone made or know of plans to make a portable welder from a generator or alternator?

: : I have seen them built from old aircraft D.C. generators.

: Saw pictures of one once that was built on a lawnmower deck. Had a 3.5 Briggs engine belted to a 12 volt alternator which charged a BIG 12 volt battery. Welding was done with battery power, and the alternator simply re-charged it. Might work for intermittent use. The system would need some means of controlling how much amperage was available at a given time, because a dead short across the battery would provide many times the desired amount. There would also be some safety considerations with such a device, including sparks getting near the gas tank, and the potential of battery explosions due to hydrogen gas accumulation during charging. I'm not saying it's a GOOD idea, just that I saw pictures of one!

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Frank

11-20-1998 09:30:15




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 Re: Re: Re: Re: Portable welder made from generator or alternator? in reply to Paul, 11-20-1998 07:04:40  
: Might work.I am really interested in driving a generator or alternator and using just the output from them.
: : : : : : : Has anyone made or know of plans to make a portable welder from a generator or alternator?

: : : I have seen them built from old aircraft D.C. generators.

: : Saw pictures of one once that was built on a lawnmower deck. Had a 3.5 Briggs engine belted to a 12 volt alternator which charged a BIG 12 volt battery. Welding was done with battery power, and the alternator simply re-charged it. Might work for intermittent use. The system would need some means of controlling how much amperage was available at a given time, because a dead short across the battery would provide many times the desired amount. There would also be some safety considerations with such a device, including sparks getting near the gas tank, and the potential of battery explosions due to hydrogen gas accumulation during charging. I'm not saying it's a GOOD idea, just that I saw pictures of one!

Check in one of the 4wd forums, the Jeep guys are always
talking about the for off road field repairs

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PHILIP

10-13-1999 00:50:06




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 Re: Re: Re: Re: Re: Portable welder made from generator or alternator? in reply to Frank, 11-20-1998 09:30:15  
I THINK IT WOULD MELT,BECAUSE,IT WOULD GET TOO HOT,AND WHERES YOUR COOLING,



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Dusty

11-22-1998 09:40:03




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 Re: Re: Re: Re: Re: Portable welder made from generator or alternator? in reply to Frank, 11-20-1998 09:30:15  
: : Might work.I am really interested in driving a generator or alternator and using just the output from them.
: : : : : : : : : Has anyone made or know of plans to make a portable welder from a generator or alternator?

: : : : I have seen them built from old aircraft D.C. generators.

: : : Saw pictures of one once that was built on a lawnmower deck. Had a 3.5 Briggs engine belted to a 12 volt alternator which charged a BIG 12 volt battery. Welding was done with battery power, and the alternator simply re-charged it. Might work for intermittent use. The system would need some means of controlling how much amperage was available at a given time, because a dead short across the battery would provide many times the desired amount. There would also be some safety considerations with such a device, including sparks getting near the gas tank, and the potential of battery explosions due to hydrogen gas accumulation during charging. I'm not saying it's a GOOD idea, just that I saw pictures of one!

: Check in one of the 4wd forums, the Jeep guys are always
: talking about the for off road field repairs

Why not use a 120/240 5000 watt (or larger) generator and plug a shop welder into it?

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Paul

11-22-1998 20:11:06




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 Re: Re: Re: Re: Re: Re: Portable welder made from generator or alternator? in reply to Dusty, 11-22-1998 09:40:03  
It would take a 12,000 watt generator for thatto get 50 amps for a welder like a Lincoln cracker box(amps x volts = watts).I have welded with one on 30 amps,but it will through the circuit breaker if you push it.That would still be 7200 watts.I have rewired a 100 amp alternator from wye to delta(increases amperage by square root of 3)and fed the output from the three phase to two seperate banks of 50 amp diodes on common heat sinks to make a positive and negative output.I regulated the field with a power rheostat.It puts out great,but is hard to keep an arc going.I was wondering if anyone else had done anything like that and had any luck with it.
: : : Might work.I am really interested in driving a generator or alternator and using just the output from them.
: : : : : : : : : : : Has anyone made or know of plans to make a portable welder from a generator or alternator?

: : : : : I have seen them built from old aircraft D.C. generators.

: : : : Saw pictures of one once that was built on a lawnmower deck. Had a 3.5 Briggs engine belted to a 12 volt alternator which charged a BIG 12 volt battery. Welding was done with battery power, and the alternator simply re-charged it. Might work for intermittent use. The system would need some means of controlling how much amperage was available at a given time, because a dead short across the battery would provide many times the desired amount. There would also be some safety considerations with such a device, including sparks getting near the gas tank, and the potential of battery explosions due to hydrogen gas accumulation during charging. I'm not saying it's a GOOD idea, just that I saw pictures of one!

: : Check in one of the 4wd forums, the Jeep guys are always
: : talking about the for off road field repairs

: Why not use a 120/240 5000 watt (or larger) generator and plug a shop welder into it?

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Tom R

11-24-1998 16:34:36




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 Re: Re: Re: Re: Re: Re: Re: Portable welder made from generator or alternator? in reply to Paul, 11-22-1998 20:11:06  
: It would take a 12,000 watt generator for thatto get 50 amps for a welder like a Lincoln cracker box(amps x volts = watts).I have welded with one on 30 amps,but it will through the circuit breaker if you push it.That would still be 7200 watts.I have rewired a 100 amp alternator from wye to delta(increases amperage by square root of 3)and fed the output from the three phase to two seperate banks of 50 amp diodes on common heat sinks to make a positive and negative output.I regulated the field with a power rheostat.It puts out great,but is hard to keep an arc going.I was wondering if anyone else had done anything like that and had any luck with it.

I built one years ago from a surplus Aircraft Generator. You need a stabilizer (inductor). As I remember I wound about 15 turns of number 8 gauge wire around a piece of 1 1/2" diameter cold roll about 10" in length. This inductor is then wired in series with one of the output leads and will stabilize the output keeping the arc from extinguishing. A reactor can be also be purchased from Burden Sales Company 1015 West "O" Street. P.O. Box 82209 Lincoln, NE. 68501-2209 Phone 800-488-3407. This is a Surplus Center, they also have the Aircraft Generators and other goodies to build your own welder. Contact them and they will send you a Catalog.

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lamont lackman

02-26-2000 13:19:24




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 Re: Re: Re: Re: Re: Re: Re: Re: Portable welder made from generator or alternator? in reply to Tom R, 11-24-1998 16:34:36  
I built one from 3 alternators and a 12 horse briggs horizontal shaft. I wired the output of one of the alternators through a bank of selectable resistors (heat settings) and used the output to excite the fields (in series) of the other two (take out all the internal regulators). Puts out good but the arc gets unstable when the diodes get hot.

The best solution I found is to throw all that stuff in the trash and buy a used crackerbox for $75.

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Patrick Delaney

04-16-2000 07:58:14




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 Re: Re: Re: Re: Re: Re: Re: Re: Re: Portable welder made from generator or alternator? in reply to lamont lackman, 02-26-2000 13:19:24  
I have found some plans to build welders from alternators.The info can be found at www.huv.com/jon/jeep/ and at www.fament.com/Chip/weld/weld.html I plan to try this myself.



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