Making an ARC Welder – Part 1 of 2

when I burned up the wires on my first

when I burned up the wires on my first metal melter I decided to turn the

metal melter I decided to turn the

metal melter I decided to turn the transformer core into a stick welder but

transformer core into a stick welder but

transformer core into a stick welder but one transformer wasn’t enough to

one transformer wasn’t enough to

one transformer wasn’t enough to actually make it weld anything in this

actually make it weld anything in this

actually make it weld anything in this project we’ll be modifying to microwave

project we’ll be modifying to microwave

project we’ll be modifying to microwave transformers because more transformers

transformers because more transformers

transformers because more transformers means more power

[Music]

[Music] for this project I scavenge parts from a

for this project I scavenge parts from a

for this project I scavenge parts from a couple more microwaves I found these for

couple more microwaves I found these for

couple more microwaves I found these for free on my local classifieds not only

free on my local classifieds not only

free on my local classifieds not only are we using twice as many transformers

are we using twice as many transformers

are we using twice as many transformers here but twice as much power seriously

here but twice as much power seriously

here but twice as much power seriously dangerous amounts of power these

dangerous amounts of power these

dangerous amounts of power these transformers are roughly the same size

transformers are roughly the same size

transformers are roughly the same size and look nearly identical except for the

and look nearly identical except for the

and look nearly identical except for the placement of the bases using an angle

placement of the bases using an angle

placement of the bases using an angle grinder we can cut down the seam of one

grinder we can cut down the seam of one

grinder we can cut down the seam of one of the shallow welds holding this base

of the shallow welds holding this base

of the shallow welds holding this base plate to the transformer the other seam

plate to the transformer the other seam

plate to the transformer the other seam is a little trickier to get to but once

is a little trickier to get to but once

is a little trickier to get to but once it’s cut you can see that the base plate

it’s cut you can see that the base plate

it’s cut you can see that the base plate can now be removed fairly easily now

can now be removed fairly easily now

can now be removed fairly easily now these next few steps are going to look a

these next few steps are going to look a

these next few steps are going to look a lot like the modification we did in the

lot like the modification we did in the

lot like the modification we did in the metal melter project after grinding the

metal melter project after grinding the

metal melter project after grinding the welds and opening the scene with a

welds and opening the scene with a

welds and opening the scene with a chisel the eye section of the

chisel the eye section of the

chisel the eye section of the transformer can be pulled back to reveal

transformer can be pulled back to reveal

transformer can be pulled back to reveal the precious primary and secondary coils

the precious primary and secondary coils

the precious primary and secondary coils I found that the primary coil can be

I found that the primary coil can be

I found that the primary coil can be removed by gently prying up with a

removed by gently prying up with a

removed by gently prying up with a chisel it’s important to work it out of

chisel it’s important to work it out of

chisel it’s important to work it out of the transformer gently because the goal

the transformer gently because the goal

the transformer gently because the goal is to keep this in perfect condition you

is to keep this in perfect condition you

is to keep this in perfect condition you might remember there are two magnetic

might remember there are two magnetic

might remember there are two magnetic shunts that get knocked out next and the

shunts that get knocked out next and the

shunts that get knocked out next and the low voltage winding gets removed because

low voltage winding gets removed because

low voltage winding gets removed because that won’t serve any purpose here now to

that won’t serve any purpose here now to

that won’t serve any purpose here now to extract the secondary coil my method of

extract the secondary coil my method of

extract the secondary coil my method of choice is to rest it loosely on the jaws

choice is to rest it loosely on the jaws

choice is to rest it loosely on the jaws of a bench vise then use a rubber hammer

of a bench vise then use a rubber hammer

of a bench vise then use a rubber hammer to knock down on the transformer until

to knock down on the transformer until

to knock down on the transformer until the coil is free this one finished up

the coil is free this one finished up

the coil is free this one finished up without any damage at all if you don’t

without any damage at all if you don’t

without any damage at all if you don’t have a bench vise you can improvise with

have a bench vise you can improvise with

have a bench vise you can improvise with a couple of blocks of wood in either

a couple of blocks of wood in either

a couple of blocks of wood in either case your secondary coils can be

case your secondary coils can be

case your secondary coils can be salvaged in near-perfect condition after

salvaged in near-perfect condition after

salvaged in near-perfect condition after a quick cleanup of the paper and resin

a quick cleanup of the paper and resin

a quick cleanup of the paper and resin our primary coil can be replaced on the

our primary coil can be replaced on the

our primary coil can be replaced on the transformer with the terminals facing

transformer with the terminals facing

transformer with the terminals facing down we’re going to be rewinding a new

down we’re going to be rewinding a new

down we’re going to be rewinding a new secondary so it’s important that we have

secondary so it’s important that we have

secondary so it’s important that we have the flat side facing up when it comes to

the flat side facing up when it comes to

the flat side facing up when it comes to winding coils life will be a lot simpler

winding coils life will be a lot simpler

winding coils life will be a lot simpler if we build a little jig I cut this

if we build a little jig I cut this

if we build a little jig I cut this piece of scrap wood so that it’s as wide

piece of scrap wood so that it’s as wide

piece of scrap wood so that it’s as wide as the center piece and just a little

as the center piece and just a little

as the center piece and just a little shorter than the top the length is cut

shorter than the top the length is cut

shorter than the top the length is cut so that it overhangs the edges by about

so that it overhangs the edges by about

so that it overhangs the edges by about half an inch on either side we can

half an inch on either side we can

half an inch on either side we can complete the form by adding a top and

complete the form by adding a top and

complete the form by adding a top and bottom panel then forming a piece of

bottom panel then forming a piece of

bottom panel then forming a piece of paper to fit the sides

paper to fit the sides

paper to fit the sides at this point I think we’re about ready

at this point I think we’re about ready

at this point I think we’re about ready to add some cable I found this 50 foot

to add some cable I found this 50 foot

to add some cable I found this 50 foot length of wire on clearance at the

length of wire on clearance at the

length of wire on clearance at the hardware store this is 8 gauge stranded

hardware store this is 8 gauge stranded

hardware store this is 8 gauge stranded copper wire and cost me about 17 dollars

copper wire and cost me about 17 dollars

copper wire and cost me about 17 dollars I’m gonna use my vise to hold the form

I’m gonna use my vise to hold the form

I’m gonna use my vise to hold the form in place and begin winding the cable

in place and begin winding the cable

in place and begin winding the cable around the center of the forum as

around the center of the forum as

around the center of the forum as tightly as possible we need to build

tightly as possible we need to build

tightly as possible we need to build this coil six turns high which isn’t too

this coil six turns high which isn’t too

this coil six turns high which isn’t too difficult first layer but gets

difficult first layer but gets

difficult first layer but gets progressively more challenging on the

progressively more challenging on the

progressively more challenging on the second layer it might seem like it’s

second layer it might seem like it’s

second layer it might seem like it’s near impossible on the third when it’s

near impossible on the third when it’s

near impossible on the third when it’s packed together six turns high and three

packed together six turns high and three

packed together six turns high and three layers deep the paper flaps can be

layers deep the paper flaps can be

layers deep the paper flaps can be folded over and taped together now this

folded over and taped together now this

folded over and taped together now this is the tricky part

is the tricky part

is the tricky part we need to unscrew the top and bottom

we need to unscrew the top and bottom

we need to unscrew the top and bottom panels to access our coil and separate

panels to access our coil and separate

panels to access our coil and separate it out of the form while keeping it all

it out of the form while keeping it all

it out of the form while keeping it all in one piece I use some electrical tape

in one piece I use some electrical tape

in one piece I use some electrical tape to ensure the coil wouldn’t unravel okay

to ensure the coil wouldn’t unravel okay

to ensure the coil wouldn’t unravel okay it’s time to transplant our new

it’s time to transplant our new

it’s time to transplant our new secondary into the transformer I have

secondary into the transformer I have

secondary into the transformer I have the best success by using a clamp to

the best success by using a clamp to

the best success by using a clamp to pitch the sides in while I push the coil

pitch the sides in while I push the coil

pitch the sides in while I push the coil down into place let’s just double-check

down into place let’s just double-check

down into place let’s just double-check the coil sits flush at the top and mix

the coil sits flush at the top and mix

the coil sits flush at the top and mix up some two-part epoxy glue to finish up

up some two-part epoxy glue to finish up

up some two-part epoxy glue to finish up just like the transformer in our metal

just like the transformer in our metal

just like the transformer in our metal melter project the entire top area gets

melter project the entire top area gets

melter project the entire top area gets a liberal coating of epoxy just before

a liberal coating of epoxy just before

a liberal coating of epoxy just before sealing it back together in order for

sealing it back together in order for

sealing it back together in order for this to form a strong bond the

this to form a strong bond the

this to form a strong bond the connection will need a lot of pressure

connection will need a lot of pressure

connection will need a lot of pressure holding it together while it sets this

holding it together while it sets this

holding it together while it sets this is where a set of clamps or a bench vise

is where a set of clamps or a bench vise

is where a set of clamps or a bench vise can be invaluable while our first

can be invaluable while our first

can be invaluable while our first transformer is setting we can prepare

transformer is setting we can prepare

transformer is setting we can prepare the second one in the exact same way our

the second one in the exact same way our

the second one in the exact same way our second coil is 18 turns of 8 gauge wire

second coil is 18 turns of 8 gauge wire

second coil is 18 turns of 8 gauge wire exactly like the first and Transplant it

exactly like the first and Transplant it

exactly like the first and Transplant it just like before don’t worry too much

just like before don’t worry too much

just like before don’t worry too much about which way the coil goes in it

about which way the coil goes in it

about which way the coil goes in it doesn’t really matter yet finally we can

doesn’t really matter yet finally we can

doesn’t really matter yet finally we can glue and clamp that together and leave

glue and clamp that together and leave

glue and clamp that together and leave it to set for around 24 hours the final

it to set for around 24 hours the final

it to set for around 24 hours the final result should look something like this

result should look something like this

result should look something like this the connection is strong and the coils

the connection is strong and the coils

the connection is strong and the coils are extremely snug so any vibrations

are extremely snug so any vibrations

are extremely snug so any vibrations will be kept to a minimum well there you

will be kept to a minimum well there you

will be kept to a minimum well there you have it the basic makings of an AC stick

have it the basic makings of an AC stick

have it the basic makings of an AC stick welding system and these two electrodes

welding system and these two electrodes

welding system and these two electrodes will eventually become our clamp and

will eventually become our clamp and

will eventually become our clamp and from this point it really doesn’t take

from this point it really doesn’t take

from this point it really doesn’t take much more to finish the system up and

much more to finish the system up and

much more to finish the system up and turn it into a useful little hobby

turn it into a useful little hobby

turn it into a useful little hobby welder look for how to do that in part

welder look for how to do that in part

welder look for how to do that in part two well that’s it for now if you liked

two well that’s it for now if you liked

two well that’s it for now if you liked this project perhaps you’ll like some of

this project perhaps you’ll like some of

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

my others check them out at the king of

my others check them out at the king of random calm

random calm

random calm [Music]