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welding and electrical

N

notjustair

Well-known Member
I always get nervous welding on vehicles of any kind that I might cook the voltage regulator or generator (or alternator). My brother supposedly ruined part of a charging system on pickup (no computer), although I don't know how well he had it grounded or where he was welding. Any stories of it happening out there? I'm not talking fuel fires or explosions - I make sure to steer clear of that possibility. Going to weld some mud flap brackets on the back of the grain truck and it got me thinking again...
 
If you disconnect the ground cable on the battery and put the welder ground clamp as close to your work as possible you should OK.I've done it that way a lot of times and never had a problem.Good Luck.
 
the ground cable is to be located right near your welding spot, not have it grounded at one end and weld on other end of vehicle. also disconnect batt.
 
I would like to know that myself. I've been told my whole life that welding on a vehicle will damage the electrical and to disconnect the battery first.
 
There's very few things as exciting as welding on a welding trailer with a shop welder while charging the trailer welder's battery. One of the best battery explosions. Too bad I had the hood down and missed the visuals.

yea, whatever
next
 
I have welded on hundreds of vehicles over the years and haven't had any major problems. I have always unhooked both battery cables.Most of the major vehicle manufacturers now do not recommend welding on vehicles at all. Ford for one says that if you have to weld on there super duty truck you must unhook both batteries, unhook and remove the computer,unhook the ABS computer, unhook and remove the dash assembly and unhook the chassis wiring harnesses. Thay also say any damage done by not doing this will not be covered under warrenty. All class 8 trucks say , unhook the batteries and computer. I have a box to hook to the batteries that is supposed to protect all circuits,but I really don't trust it.
 
Welder type enters into the problem. AC welders have very few problems with stray voltages. A DC welder is very unpredictable about where stray voltages may damage electrical equipment, even when grounded very close to job.

Co-worker once fried the motor and control system in our warehouse feeder system. Was welding with DC. We had always been advised to use AC when working on this equioment.

Gene
 
It makes me nervous also when automotive computers are concerned. Youre working with voltages HIGHER then those normally used in the auto electrical system,,,,,,,, youre passing wayyyyyy more current through certain parts,,,,,,,,sensitive electronics arent real fond of voltage or current spikes etc,,,,,,,,,,currtent will seek all available paths (perhaps via an electronic component)

SO IF I WAS GOING TO WELD ON A LATE MODEL CAR ID TAKE ALL NECESSARY PRECAUTIONS (disconnecting battery and computers etc as recommended)

BUT if others dont care to do that its their car amd money and their risk NOT mine but in good faith and conscience I just have to recommend following the manufacturers aDVICE over opinions posted here, including mine, now you and others are free to do as you like.......

John T
 
Learned first hand about welding on a Ford . My 88 Ford F350 needed a exhaust bracket welded , not a big deal we have a mig welder and know how to use it . I go unhook the battery both cables put the floor jack under the muffler grind off the rust ground wright next to the weld and make a little two inch weld both sides . Get out from under truck and re hook up the batterys and go to back the truck out of the shop. AH why won't this thing fire up checked everything and then got the scanner out and to my surprise i now have a well done frayed computer . Not a big problem , nothing that a new computer will not fix . That is when i learned that ya got to remove and get the computer away from the truck and the welding area. On older trucks i have always unhooked the battery and the charging system and if welding close to the batterys then remove them far away from any sparks.
 
Another problem is having welding current pass through a precision bearing. Imagine arcing in a tapered roller or ball bearing.
 
How about adding a second ground that is tied directly to earth? Can we be 100% sure that the "ground" lead is grouned to earth? I have not taken a welder apart but I know you can change the polarity of a dc rig.
 
The grain truck is a 1958 - no computer - so I think I will just remove the negative cable and go after it. I have welded on the back of the same truck without removing the cable, but the last thing I want to do is fool with rebuilding that generator. Thanks guys!

PS - You WILL NOT catch me welding on my '07 pickup. Everything is controlled by a nanny on it. I can't imagine what stray current would do to it!
 
I have done some welding on the exhaust on a 1997 GMC Sierra as well as a 98 Toyota Camry. I disconnect the - battery cable and get the ground as close as possible to where I'm welding. Obviously you wouldn't want to ground to the frame and weld the exhaust. The current would be forced through the frame, to the engine and down to you. Turned out all right so far,I see no reason to stop. Just use proper precautions.
 
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