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My Home Made Welder - and a few questions

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  • My Home Made Welder - and a few questions

    I made another crazy thing - this is different than my
    Generator, It does look similar - I used the same type motor
    and cart

    Briggs 6.5hp Intek motor - like my
    Home Made Generator


    Chrysler Alternator 75amp - for charging the battery

    Chevy CS130 Alternator 105amp - For welding, the regulator has
    been removed, the diodes and case upgraded with a Iceberg Kit,
    three 50 Amp diodes, and 12v now goes directly to the rotor field
    brush from the battery

    2 gauge welding cable

    A rheostat to vary the power going to the field of the welding
    alternator

    ---------------------------------------------------------------


    But and here is a problem - I cant seam to weld,
    it tries but it wont be stable, and the blobs
    of welder rod dont even stick to the metal
    I only tried 3/32" rods, guess I could try 1/16"
    but that would mean that I am getting less than
    40amps

    I thought it might be a shorted rotor but the rotor
    reads 6.8 ohm

    I thought it might be the speed that the alternator is
    going but the 5 inch pulley - should be putting the
    Alternators at about 9000rpm - I think
    , a 6 inch pulley
    should do 10800

    any I deas

    Its most likey something simple

    Thanks
    Attached Files

  • #2
    a few more pics
    Attached Files

    Comment


    • #3
      Its not done yet - still need to make a belt gaurd
      and reinforce the thing that holds the alternators
      paint it, add a battery box- ect ect

      I may try another Chrysler Alternator to replace the cs130
      - I got a 100amp it looks like the alternator on the top

      Comment


      • #4
        dude you really need to just buy a welder, they're so cheap

        sounds like the power just isn't sufficient

        James
        www.digital-car.co.uk - The UK CarPC Forum

        Comment


        • #5
          hhahahah man i love ur creations it looks awsome but yeah id buy my own welder cuz u dont want to weld on a muffler and then think its fine and drive down the road and then come home witout a muffler :-P

          Comment


          • #6
            Originally posted by Jamez_Warner
            dude you really need to just buy a welder, they're so cheap

            sounds like the power just isn't sufficient

            James

            Well the problem is that - you cant buy a 100% duty cycle
            welder cheap - plus I want a gas powered welder, and you
            are money ahead to make your own - thay cost $1000
            and up - used - and $2000-$3000 or more new

            I might have spent about $300 so far -

            Plus I have seen alternator/welders work - and there are lots
            of peeps on the internet that say they work good, so I am
            doing somthing wrong - I should be getting about 100amp

            I am going to check the diodes

            Comment


            • #7
              I have a few of those diy welder pages bookmarked. I'd like to try one out sometime. Could having 2 alternators on that belt be bogging down the engine enough that you're not getting your 100 amps? Shouldn't need the smaller one anyways, right? Good luck.
              '03 Acura 3.2TL Type S
              '04 Buick Rainier, factory nav
              '99 Honda Shadow 1100

              -8" Lilliput TS, laptop, (too) large inverter, and I'm nowhere near putting them anywhere.

              For Sale!

              Comment


              • #8
                Originally posted by mjd932
                I have a few of those diy welder pages bookmarked. I'd like to try one out sometime. Could having 2 alternators on that belt be bogging down the engine enough that you're not getting your 100 amps? Shouldn't need the smaller one anyways, right? Good luck.

                I think something is not right about my setup - I put a heavy duty
                100amp Chrysler alternator, on the bottom - I was using that small
                one to try to weld

                I am getting the same thing - sparks but no welding - so its not the
                alternator, I think its the RPM - I think I need a 6 or 7 inch pulley
                on my motor

                the funny thing is the motor is not even straining - I dont think
                there is any load on the motor, and from what I hear it should
                almost stall my 6hp motor

                Comment


                • #9
                  http://oak.cats.ohiou.edu/~weinfurt/gaswelder.html

                  From all the projects I looked up they only used one alternator. This one here uses a chrysler alternator (no buiilt in regulator like the gm ones). Maybe going with that larger pulley will speed up the belt enough to get you those 100 amps.
                  '03 Acura 3.2TL Type S
                  '04 Buick Rainier, factory nav
                  '99 Honda Shadow 1100

                  -8" Lilliput TS, laptop, (too) large inverter, and I'm nowhere near putting them anywhere.

                  For Sale!

                  Comment


                  • #10
                    Originally posted by mjd932
                    http://oak.cats.ohiou.edu/~weinfurt/gaswelder.html

                    From all the projects I looked up they only used one alternator. This one here uses a chrysler alternator (no buiilt in regulator like the gm ones). Maybe going with that larger pulley will speed up the belt enough to get you those 100 amps.
                    I got the alternators wired to do different things - and a switch for each
                    to turn the field off, only one welds, but yea its got to be RPM

                    I am going to rip the diodes out of the welding alternator
                    and replace with 600v 40amp stud mount diodes on a external
                    heatsinks

                    should be a monster
                    Attached Files

                    Comment


                    • #11
                      not enough friction on the bottom pulley

                      I know this is an old post but I just had to say something. This isn't an rpm issue or a problem with the alternator. It is a mechanical engineering problem. The belt touches the bottom alternator just slightly, maybe 10-20% of its circumference. When you get 20 amps or more of current of welding off that alternator, it may be 30 volts at 20 amps or 600 watts. No matter how tight that belt, you can't transfer almost a horse power with that little bit of surface area. In other words, when you get up to a certain power, the pulley for the welding alternator is slipping. But you can't see that at the time and of course you can't hear it with the engine going and revving up. The easy fix is to swap the two alternators. The one on top doesn't need a lot of power so should do fine in the bottom position. The top pulley has a good wrap with the belt.

                      The other option is to get a tensioner pulley. They aren't there to keep tension. The real purpose is to make the belt wrap around the pulley more than it would without the tensioner. You would have to get a longer belt though.

                      Just remember, you might try to weld with up to 80 volts and 100 amps. That is 8,000 watts of power. That is 10 hp. But even if you just wanted 5 hp (plenty for welding most things) then you would need a couple of hundred pounds of bearing force due to the belt tightness. And that is based on 180 degree belt "wrap". In the current setup with only 60 degree wrap, then you would need so much belt tension that the belt would snap.

                      Anyway, hope this helps.

                      Richard
                      http://PoorManGuides.blogspot.com/
                      http://PoorManGuides.net

                      Comment


                      • #12
                        This is old but I've tried to do this too with a CS130. It just doesn't work. I have mine mounted to an AMC 360 engine that resides in my jeep. I wanted to build an on-board welder but it won't arc. It just sparks. I got my engine up to 4000 rpms and it stil doesn't work. It gets extremely hot but will not weld.

                        I was really hoping the OP could come back with some updates. My thread about my build is here:

                        http://www.pirate4x4.com/forum/showt...=1#post9984562

                        Comment


                        • #13
                          Why not just get a Used HO alt from off a Car audio site, I see them all the time. SInce its not specific to a car (in your case) You can get them.

                          realmofexcursion.com
                          caraudio.com
                          soundsolution.com

                          Comment


                          • #14
                            I had heard you could do this with the CS130s so I gave it a try. The best alternator to use is the Ford's with the external regulator. Simple and easy. I got this one for $10 so I figured I'd give it a shot.

                            Also, the voltage coming out was only 29 volts. You'd need at least 60 or better. I'm still hoping the OP will show up with a few answers.

                            Comment


                            • #15
                              Originally posted by McCracken View Post
                              This is old but I've tried to do this too with a CS130. It just doesn't work. I have mine mounted to an AMC 360 engine that resides in my jeep. I wanted to build an on-board welder but it won't arc. It just sparks. I got my engine up to 4000 rpms and it stil doesn't work. It gets extremely hot but will not weld.

                              I was really hoping the OP could come back with some updates. My thread about my build is here:

                              http://www.pirate4x4.com/forum/showt...=1#post9984562

                              Lol mine to, never got it to work, I tried all kinds of stuff,
                              but never tried a wider belt, its sitting dissembled right now,
                              I was going to look into the Zena welder, but got side tracked and
                              needed a welder right then and there ended up getting the
                              Miller Thunderbolt XL 225 AC/DC stick welder, I set it at 90amps AC
                              and weld all day with it, - I still want a portable welder, but its
                              going to be a long time

                              BTW I hear its better to use 24 volt alternators

                              also look here
                              BUILD A $20 PORTABLE DC ARC WELDER

                              we must be doing something wrong

                              Comment

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