Make a Spot Welder for Cheap!!

a typical resistant spot welder like

a typical resistant spot welder like this can range in price from around $200

this can range in price from around $200

this can range in price from around $200 to over 800 that’s a little out of my

to over 800 that’s a little out of my

to over 800 that’s a little out of my price range so for this project let’s

price range so for this project let’s

price range so for this project let’s make this one from common materials and

make this one from common materials and

make this one from common materials and for just a few bucks

this modified transformer is the heart

this modified transformer is the heart of the spot welder and you might

of the spot welder and you might

of the spot welder and you might remember it as the metal melter if this

remember it as the metal melter if this

remember it as the metal melter if this doesn’t look familiar

doesn’t look familiar

doesn’t look familiar check out how this was made and what it

check out how this was made and what it

check out how this was made and what it can do in some of my other videos I

can do in some of my other videos I

can do in some of my other videos I found a practical application for it in

found a practical application for it in

found a practical application for it in making a spot welder like this one to

making a spot welder like this one to

making a spot welder like this one to get started I’m gonna measure the base

get started I’m gonna measure the base

get started I’m gonna measure the base of the transformer and it looks like

of the transformer and it looks like

of the transformer and it looks like it’s about four and a quarter inches

it’s about four and a quarter inches

it’s about four and a quarter inches wide

wide

wide I found a six-foot piece of one by six

I found a six-foot piece of one by six

I found a six-foot piece of one by six common board that will be perfect for

common board that will be perfect for

common board that will be perfect for this using my chop saw cut two pieces of

this using my chop saw cut two pieces of

this using my chop saw cut two pieces of the board so that they’re both 12 inches

the board so that they’re both 12 inches

the board so that they’re both 12 inches long then another piece gets cut at 42

long then another piece gets cut at 42

long then another piece gets cut at 42 inches I’m trimming this piece down with

inches I’m trimming this piece down with

inches I’m trimming this piece down with my table saw so that it’s about a

my table saw so that it’s about a

my table saw so that it’s about a quarter inch wider than the transformer

quarter inch wider than the transformer

quarter inch wider than the transformer base and in this case that measures out

base and in this case that measures out

base and in this case that measures out at four and a half inches then it gets

at four and a half inches then it gets

at four and a half inches then it gets chopped into three different lengths

chopped into three different lengths

chopped into three different lengths measuring 24 inches 12 inches and 4

measuring 24 inches 12 inches and 4

measuring 24 inches 12 inches and 4 inches next I found a 2 by 2 and I’m

inches next I found a 2 by 2 and I’m

inches next I found a 2 by 2 and I’m cutting the nicest parts of the beam

cutting the nicest parts of the beam

cutting the nicest parts of the beam into two pieces measuring 13 and a half

into two pieces measuring 13 and a half

into two pieces measuring 13 and a half inches long two other pieces are cut at

inches long two other pieces are cut at

inches long two other pieces are cut at 4 inches and everything can be placed

4 inches and everything can be placed

4 inches and everything can be placed together to see how it fits that’s the

together to see how it fits that’s the

together to see how it fits that’s the rough idea right there and I’d like to

rough idea right there and I’d like to

rough idea right there and I’d like to knock down the sharp edges so I found a

knock down the sharp edges so I found a

knock down the sharp edges so I found a 3/4 inch rounding bit and routed the

3/4 inch rounding bit and routed the

3/4 inch rounding bit and routed the appropriate edges to give it a smoother

appropriate edges to give it a smoother

appropriate edges to give it a smoother feel these front pieces are going to be

feel these front pieces are going to be

feel these front pieces are going to be my electrode holders the edge of this

my electrode holders the edge of this

my electrode holders the edge of this scrap piece of wood works as a template

scrap piece of wood works as a template

scrap piece of wood works as a template to draw a 90-degree angle into the top

to draw a 90-degree angle into the top

to draw a 90-degree angle into the top piece about an inch from the end I don’t

piece about an inch from the end I don’t

piece about an inch from the end I don’t have a bandsaw so I’m improvising with

have a bandsaw so I’m improvising with

have a bandsaw so I’m improvising with my bench vise and a jig saw to cut this

my bench vise and a jig saw to cut this

my bench vise and a jig saw to cut this piece out and it worked

piece out and it worked

piece out and it worked you’ll see what this groove is for in a

you’ll see what this groove is for in a

you’ll see what this groove is for in a bit the next part is to cut out the

bit the next part is to cut out the

bit the next part is to cut out the pattern I drew on the back panel so I’m

pattern I drew on the back panel so I’m

pattern I drew on the back panel so I’m gonna utilize my vise once again and use

gonna utilize my vise once again and use

gonna utilize my vise once again and use an 1132 drill bit to cut holes in all

an 1132 drill bit to cut holes in all

an 1132 drill bit to cut holes in all the corners so I can get back in there

the corners so I can get back in there

the corners so I can get back in there with my jig saw these holes will be for

with my jig saw these holes will be for

with my jig saw these holes will be for a switch and a power cord and all this

a switch and a power cord and all this

a switch and a power cord and all this panel needs now are two pilot holes

panel needs now are two pilot holes

panel needs now are two pilot holes drilled in the appropriate places for

drilled in the appropriate places for

drilled in the appropriate places for the switch

the switch

the switch I’m thinking I should give this a paint

I’m thinking I should give this a paint

I’m thinking I should give this a paint job so all the panels get sanded with an

job so all the panels get sanded with an

job so all the panels get sanded with an orbital sander then laid out for priming

orbital sander then laid out for priming

orbital sander then laid out for priming and painting four colors I’m thinking

and painting four colors I’m thinking

and painting four colors I’m thinking black and yellow with the paint drying

black and yellow with the paint drying

black and yellow with the paint drying I’ve gathered up a few components that

I’ve gathered up a few components that

I’ve gathered up a few components that were saved from the same microwave I got

were saved from the same microwave I got

were saved from the same microwave I got the transformer from to see all the

the transformer from to see all the

the transformer from to see all the amazing things that I got from that

amazing things that I got from that

amazing things that I got from that project make sure you check out my video

project make sure you check out my video

project make sure you check out my video on salvaging a microwave I found in my

on salvaging a microwave I found in my

on salvaging a microwave I found in my neighbor’s trash can I’m gonna use the

neighbor’s trash can I’m gonna use the

neighbor’s trash can I’m gonna use the power cord

power cord

power cord these wired Spade connectors the door

these wired Spade connectors the door

these wired Spade connectors the door handle and this contact switch aside

handle and this contact switch aside

handle and this contact switch aside from the wood the only parts I needed to

from the wood the only parts I needed to

from the wood the only parts I needed to buy were a single pole light switch with

buy were a single pole light switch with

buy were a single pole light switch with matching cover copper offset terminal

matching cover copper offset terminal

matching cover copper offset terminal lugs a couple of quarter-inch thick

lugs a couple of quarter-inch thick

lugs a couple of quarter-inch thick screws two small nails and a length of

screws two small nails and a length of

screws two small nails and a length of six gauge solid copper wire the copper

six gauge solid copper wire the copper

six gauge solid copper wire the copper wire gets marked off in one inch

wire gets marked off in one inch

wire gets marked off in one inch increments and two pieces are cut off

increments and two pieces are cut off

increments and two pieces are cut off using the wire cutter on my pliers these

using the wire cutter on my pliers these

using the wire cutter on my pliers these are gonna work as my welding tips the

are gonna work as my welding tips the

are gonna work as my welding tips the copper lugs have an adjustable screw

copper lugs have an adjustable screw

copper lugs have an adjustable screw that can be loosened to insert the solid

that can be loosened to insert the solid

that can be loosened to insert the solid copper wire when it’s tightened back up

copper wire when it’s tightened back up

copper wire when it’s tightened back up it looks like this

it looks like this

it looks like this alright the paint on the wood panels is

alright the paint on the wood panels is

alright the paint on the wood panels is dry and I’ve added the switch to the

dry and I’ve added the switch to the

dry and I’ve added the switch to the back panel to make sure it fits so the

back panel to make sure it fits so the

back panel to make sure it fits so the next step is to flip it over and press

next step is to flip it over and press

next step is to flip it over and press the power cord down into the hole at the

the power cord down into the hole at the

the power cord down into the hole at the bottom the thick piece at the end of the

bottom the thick piece at the end of the

bottom the thick piece at the end of the cord prevents it from pulling back

cord prevents it from pulling back

cord prevents it from pulling back through the hole I’m ready to pieces

through the hole I’m ready to pieces

through the hole I’m ready to pieces back together so I’m drilling a couple

back together so I’m drilling a couple

back together so I’m drilling a couple of pilot holes into the bottom and

of pilot holes into the bottom and

of pilot holes into the bottom and securing the back panel with a couple of

securing the back panel with a couple of

securing the back panel with a couple of screws now the front 2×2 supports are

screws now the front 2×2 supports are

screws now the front 2×2 supports are added and the metal melter is placed on

added and the metal melter is placed on

added and the metal melter is placed on the base about an inch back from the

the base about an inch back from the

the base about an inch back from the supports I’ll add a screw to one of the

supports I’ll add a screw to one of the

supports I’ll add a screw to one of the corners to help keep it in place and at

corners to help keep it in place and at

corners to help keep it in place and at this point I’m ready to rig up the

this point I’m ready to rig up the

this point I’m ready to rig up the electrical system taking the green wire

electrical system taking the green wire

electrical system taking the green wire from the power cord I’m stripping open a

from the power cord I’m stripping open a

from the power cord I’m stripping open a gap in the plastic to expose the bare

gap in the plastic to expose the bare

gap in the plastic to expose the bare cord this will wrap around the grounding

cord this will wrap around the grounding

cord this will wrap around the grounding screw on the power switch the end of the

screw on the power switch the end of the

screw on the power switch the end of the wire has a hole I can use to insert

wire has a hole I can use to insert

wire has a hole I can use to insert another short screw and work that down

another short screw and work that down

another short screw and work that down into the opposite corner of the

into the opposite corner of the

into the opposite corner of the transformer base not only does this

transformer base not only does this

transformer base not only does this secure the metal melter in place it also

secure the metal melter in place it also

secure the metal melter in place it also grounds out the transformer core at the

grounds out the transformer core at the

grounds out the transformer core at the same time okay I’ve exposed the copper

same time okay I’ve exposed the copper

same time okay I’ve exposed the copper on the black wire and that’ll get

on the black wire and that’ll get

on the black wire and that’ll get connected to the bottom terminal of the

connected to the bottom terminal of the

connected to the bottom terminal of the power switch and screw

power switch and screw

power switch and screw kite this Salvage Spade connector still

kite this Salvage Spade connector still

kite this Salvage Spade connector still fits onto one of the Transformers

fits onto one of the Transformers

fits onto one of the Transformers primary terminals so with that on the

primary terminals so with that on the

primary terminals so with that on the other end of the wire can be connected

other end of the wire can be connected

other end of the wire can be connected to the top terminal of the power switch

to the top terminal of the power switch

to the top terminal of the power switch now the switch can be screwed down

now the switch can be screwed down

now the switch can be screwed down permanently and a cover plate added to

permanently and a cover plate added to

permanently and a cover plate added to protect from electric shock and to make

protect from electric shock and to make

protect from electric shock and to make it look nice the other Spade connector

it look nice the other Spade connector

it look nice the other Spade connector that was salvaged goes on the left

that was salvaged goes on the left

that was salvaged goes on the left terminal of the primary coil and we

terminal of the primary coil and we

terminal of the primary coil and we could finish the electrical here

could finish the electrical here

could finish the electrical here but I want to add one more switch for

but I want to add one more switch for

but I want to add one more switch for convenience this switch still has the

convenience this switch still has the

convenience this switch still has the original wires and connectors from the

original wires and connectors from the

original wires and connectors from the microwave and I’ve just added a wrap of

microwave and I’ve just added a wrap of

microwave and I’ve just added a wrap of electrical tape to make sure I don’t get

electrical tape to make sure I don’t get

electrical tape to make sure I don’t get shocked while touching it I’ll strip the

shocked while touching it I’ll strip the

shocked while touching it I’ll strip the end of the white wire and twist it

end of the white wire and twist it

end of the white wire and twist it together with the other white wire

together with the other white wire

together with the other white wire coming off the primary then use a wire

coming off the primary then use a wire

coming off the primary then use a wire nut to cover the connection now the

nut to cover the connection now the

nut to cover the connection now the black wire is joined with the white wire

black wire is joined with the white wire

black wire is joined with the white wire coming from the power cable and the

coming from the power cable and the

coming from the power cable and the electrical system is complete I added

electrical system is complete I added

electrical system is complete I added this microwave door handle to the top

this microwave door handle to the top

this microwave door handle to the top panel and I’m screwing it on to see how

panel and I’m screwing it on to see how

panel and I’m screwing it on to see how it holds up the alignment looks good

it holds up the alignment looks good

it holds up the alignment looks good when I pick it up it seems to support

when I pick it up it seems to support

when I pick it up it seems to support the weight without any problem alright

the weight without any problem alright

the weight without any problem alright with the cables laying out the front

with the cables laying out the front

with the cables laying out the front it’s time to close up the side panels

it’s time to close up the side panels

it’s time to close up the side panels and I’m doing that by drilling holes and

and I’m doing that by drilling holes and

and I’m doing that by drilling holes and adding six screws on each panel to make

adding six screws on each panel to make

adding six screws on each panel to make sure it’s held securely the next step is

sure it’s held securely the next step is

sure it’s held securely the next step is to construct these electrode holders I

to construct these electrode holders I

to construct these electrode holders I chose to use a 3/16 bit to drill a hole

chose to use a 3/16 bit to drill a hole

chose to use a 3/16 bit to drill a hole into both tips of the two by twos which

into both tips of the two by twos which

into both tips of the two by twos which you can see got painted yellow the hole

you can see got painted yellow the hole

you can see got painted yellow the hole is big enough to prevent the wood from

is big enough to prevent the wood from

is big enough to prevent the wood from splitting when these screws go in yet

splitting when these screws go in yet

splitting when these screws go in yet small enough to hold them in secure this

small enough to hold them in secure this

small enough to hold them in secure this is the top piece and I’m gonna add a

is the top piece and I’m gonna add a

is the top piece and I’m gonna add a switch to the side about half an inch

switch to the side about half an inch

switch to the side about half an inch from the tip it gets set at a slight

from the tip it gets set at a slight

from the tip it gets set at a slight angle and the two small nails are

angle and the two small nails are

angle and the two small nails are hammered down into the holes already in

hammered down into the holes already in

hammered down into the holes already in the switch now the two beams can be slid

the switch now the two beams can be slid

the switch now the two beams can be slid into the front of the casing with one

into the front of the casing with one

into the front of the casing with one under the wire and the other over top to

under the wire and the other over top to

under the wire and the other over top to secure them in place I’m using some

secure them in place I’m using some

secure them in place I’m using some scrap wood to keep them an equal

scrap wood to keep them an equal

scrap wood to keep them an equal distance apart as I drill a hole through

distance apart as I drill a hole through

distance apart as I drill a hole through the side of the casing and into the beam

the side of the casing and into the beam

the side of the casing and into the beam I’ve pushed a nail into the hole and now

I’ve pushed a nail into the hole and now

I’ve pushed a nail into the hole and now you can see this top piece is able to

you can see this top piece is able to

you can see this top piece is able to pivot freely it should be obvious now

pivot freely it should be obvious now

pivot freely it should be obvious now why we needed that notch near the base

why we needed that notch near the base

why we needed that notch near the base the bottom beam also gets a hole drilled

the bottom beam also gets a hole drilled

the bottom beam also gets a hole drilled on either side as well as its own set of

on either side as well as its own set of

on either side as well as its own set of nails to keep it from sliding around the

nails to keep it from sliding around the

nails to keep it from sliding around the welding tips can be attached now so we

welding tips can be attached now so we

welding tips can be attached now so we push one of the hex screws through the

push one of the hex screws through the

push one of the hex screws through the hole in the lug and then join it to the

hole in the lug and then join it to the

hole in the lug and then join it to the right side cable that gets tightened

right side cable that gets tightened

right side cable that gets tightened securely into our pilot hole and all

securely into our pilot hole and all

securely into our pilot hole and all that gets repeated on the top

that gets repeated on the top

that gets repeated on the top the misalignments can be fixed by

the misalignments can be fixed by

the misalignments can be fixed by bending the lugs slightly inward and now

bending the lugs slightly inward and now

bending the lugs slightly inward and now we’ve got perfect contact to finish this

we’ve got perfect contact to finish this

we’ve got perfect contact to finish this off I’d like a way for the top beam to

off I’d like a way for the top beam to

off I’d like a way for the top beam to stay suspended on its own so to address

stay suspended on its own so to address

stay suspended on its own so to address the challenge I’ll add a couple of

the challenge I’ll add a couple of

the challenge I’ll add a couple of screws and a thick rubber band the

screws and a thick rubber band the

screws and a thick rubber band the system is finished my very own spot

system is finished my very own spot

system is finished my very own spot welder and for less than $10 in

welder and for less than $10 in

welder and for less than $10 in materials let’s see if it works

materials let’s see if it works

materials let’s see if it works power cord plugs in and with the

power cord plugs in and with the

power cord plugs in and with the electrode tips touching I’ll press the

electrode tips touching I’ll press the

electrode tips touching I’ll press the button to engage but nothing’s happening

button to engage but nothing’s happening

button to engage but nothing’s happening well that’s because the safety switch is

well that’s because the safety switch is

well that’s because the safety switch is still off let’s try it again this time

still off let’s try it again this time

still off let’s try it again this time when I press the button the system hums

when I press the button the system hums

when I press the button the system hums and when the tips touch I see the Hiab

and when the tips touch I see the Hiab

and when the tips touch I see the Hiab sparks I was hoping for I don’t have any

sparks I was hoping for I don’t have any

sparks I was hoping for I don’t have any sheet metal handy so I decided to try

sheet metal handy so I decided to try

sheet metal handy so I decided to try using these washers for my first

using these washers for my first

using these washers for my first experiment the pressure holds them in

experiment the pressure holds them in

experiment the pressure holds them in place hands-free and with the system

place hands-free and with the system

place hands-free and with the system energized it only takes about three

energized it only takes about three

energized it only takes about three seconds to fuse them together

seconds to fuse them together

seconds to fuse them together I’m trying it again with a third washer

I’m trying it again with a third washer

I’m trying it again with a third washer being careful not to touch these because

being careful not to touch these because

being careful not to touch these because they’re extremely high surprisingly it

they’re extremely high surprisingly it

they’re extremely high surprisingly it even worked on thicker welds like

even worked on thicker welds like

even worked on thicker welds like melting a washer to this steel spike

melting a washer to this steel spike

melting a washer to this steel spike trying to break them apart by hand was a

trying to break them apart by hand was a

trying to break them apart by hand was a fruitless effort so I tried using pliers

fruitless effort so I tried using pliers

fruitless effort so I tried using pliers and even that was a bit of a challenge

and even that was a bit of a challenge

and even that was a bit of a challenge but I got it that just goes to show the

but I got it that just goes to show the

but I got it that just goes to show the welds are pretty strong a feature I

welds are pretty strong a feature I

welds are pretty strong a feature I really like about this design is that

really like about this design is that

really like about this design is that the electrode holders can be removed

the electrode holders can be removed

the electrode holders can be removed allowing the user to extend the welders

allowing the user to extend the welders

allowing the user to extend the welders reach and access difficult angles they

reach and access difficult angles they

reach and access difficult angles they go back in as easily as they came out

go back in as easily as they came out

go back in as easily as they came out and all it takes to secure them back in

and all it takes to secure them back in

and all it takes to secure them back in place is a little wiggle and the

place is a little wiggle and the

place is a little wiggle and the replacement of the locking nails the

replacement of the locking nails the

replacement of the locking nails the elastic band is easy to replace and it’s

elastic band is easy to replace and it’s

elastic band is easy to replace and it’s doing a great job providing back tension

doing a great job providing back tension

doing a great job providing back tension after I make a connection

after I make a connection

after I make a connection I tried welding a couple of iron nails

I tried welding a couple of iron nails

I tried welding a couple of iron nails in an X pattern and since the heat was

in an X pattern and since the heat was

in an X pattern and since the heat was concentrated in the center it didn’t

concentrated in the center it didn’t

concentrated in the center it didn’t burn my fingers the power of the metal

burn my fingers the power of the metal

burn my fingers the power of the metal melter is still evident in the way the

melter is still evident in the way the

melter is still evident in the way the iron is boiling on this nail and if

iron is boiling on this nail and if

iron is boiling on this nail and if allowed to continue the nail melts down

allowed to continue the nail melts down

allowed to continue the nail melts down into a little ball of liquid metal when

into a little ball of liquid metal when

into a little ball of liquid metal when it’s time to replace the electrode tips

it’s time to replace the electrode tips

it’s time to replace the electrode tips just loosen the tensioner remove the

just loosen the tensioner remove the

just loosen the tensioner remove the spent electrode and replace with a fresh

spent electrode and replace with a fresh

spent electrode and replace with a fresh piece of your copper wire if you do it

piece of your copper wire if you do it

piece of your copper wire if you do it this way you can get about 12 tips for a

this way you can get about 12 tips for a

this way you can get about 12 tips for a buck because the wire is not that

buck because the wire is not that

buck because the wire is not that expensive well now you know how to make

expensive well now you know how to make

expensive well now you know how to make my version of a spot welder from easily

my version of a spot welder from easily

my version of a spot welder from easily accessible and low-cost parts if you

accessible and low-cost parts if you

accessible and low-cost parts if you like this project perhaps you’ll like

like this project perhaps you’ll like

like this project perhaps you’ll like some of my others check them out at the

some of my others check them out at the

some of my others check them out at the king of random calm