Making an ARC Welder – Part 2 of 2

in part one of this project we scavenged

in part one of this project we scavenged some parts from household appliances and

some parts from household appliances and

some parts from household appliances and modified them so we could weld metal in

modified them so we could weld metal in

modified them so we could weld metal in this project we’ll be rigging up the

this project we’ll be rigging up the

this project we’ll be rigging up the electrical system and adding some

electrical system and adding some

electrical system and adding some finishing touches so that our homemade

finishing touches so that our homemade

finishing touches so that our homemade stick welder is ready for operation

[Music]

[Music] I started this project with a scrap

I started this project with a scrap

I started this project with a scrap piece of 3/4 inch plywood that I had

piece of 3/4 inch plywood that I had

piece of 3/4 inch plywood that I had leftover from the router table project

leftover from the router table project

leftover from the router table project and since we have a router table

and since we have a router table

and since we have a router table let’s profile the edges with a beading

let’s profile the edges with a beading

let’s profile the edges with a beading bit just because we can next let’s cut a

bit just because we can next let’s cut a

bit just because we can next let’s cut a piece of 2×2 and screw it in from the

piece of 2×2 and screw it in from the

piece of 2×2 and screw it in from the bottom so that it’s secured in the

bottom so that it’s secured in the

bottom so that it’s secured in the center and about 1 inch from the edge

center and about 1 inch from the edge

center and about 1 inch from the edge we’ll also need to drill a couple of

we’ll also need to drill a couple of

we’ll also need to drill a couple of pilot holes in the top because this is

pilot holes in the top because this is

pilot holes in the top because this is where we’ll be attaching some copper

where we’ll be attaching some copper

where we’ll be attaching some copper lugs to make these we simply take a

lugs to make these we simply take a

lugs to make these we simply take a piece of half-inch copper tubing and use

piece of half-inch copper tubing and use

piece of half-inch copper tubing and use a hacksaw to cut 2 inches from the end

a hacksaw to cut 2 inches from the end

a hacksaw to cut 2 inches from the end half of the tube can be placed in the

half of the tube can be placed in the

half of the tube can be placed in the jaws of a bench vise and when the vise

jaws of a bench vise and when the vise

jaws of a bench vise and when the vise is closed with a significant amount of

is closed with a significant amount of

is closed with a significant amount of force you can see that we’re left with a

force you can see that we’re left with a

force you can see that we’re left with a nice flat end let’s place that on

nice flat end let’s place that on

nice flat end let’s place that on another piece of scrap wood and drill a

another piece of scrap wood and drill a

another piece of scrap wood and drill a 5/32 inch hole so that it penetrates

5/32 inch hole so that it penetrates

5/32 inch hole so that it penetrates through to the other side I’ve done this

through to the other side I’ve done this

through to the other side I’ve done this with four different pieces and to clean

with four different pieces and to clean

with four different pieces and to clean up the rough metal Barb’s I’m using a

up the rough metal Barb’s I’m using a

up the rough metal Barb’s I’m using a belt sander to gently follow at the

belt sander to gently follow at the

belt sander to gently follow at the edges until it looks a little more

edges until it looks a little more

edges until it looks a little more user-friendly this lug here is going to

user-friendly this lug here is going to

user-friendly this lug here is going to attach to a five foot length of 8 gauge

attach to a five foot length of 8 gauge

attach to a five foot length of 8 gauge cable this was leftover from when we

cable this was leftover from when we

cable this was leftover from when we wound our coils

wound our coils

wound our coils we’ll just need to strip about two

we’ll just need to strip about two

we’ll just need to strip about two inches of insulation from the ends to

inches of insulation from the ends to

inches of insulation from the ends to expose the copper wire then bend the

expose the copper wire then bend the

expose the copper wire then bend the wire over with a pair of pliers to form

wire over with a pair of pliers to form

wire over with a pair of pliers to form a little loop the exposed copper loop

a little loop the exposed copper loop

a little loop the exposed copper loop can be slid inside the casing and to

can be slid inside the casing and to

can be slid inside the casing and to make this a permanent connection

make this a permanent connection

make this a permanent connection let’s crimp it onto the cable using the

let’s crimp it onto the cable using the

let’s crimp it onto the cable using the bench vise like we did before this

bench vise like we did before this

bench vise like we did before this connection isn’t coming apart and should

connection isn’t coming apart and should

connection isn’t coming apart and should easily handle the high currents that

easily handle the high currents that

easily handle the high currents that we’ll be exposing it to

we’ll be exposing it to

we’ll be exposing it to the other end of this cable will be our

the other end of this cable will be our

the other end of this cable will be our ground clamp I got this metal clamp for

ground clamp I got this metal clamp for

ground clamp I got this metal clamp for 99 cents and with the rubber tips

99 cents and with the rubber tips

99 cents and with the rubber tips removed

removed

removed it’ll conduct electricity i crimped a

it’ll conduct electricity i crimped a

it’ll conduct electricity i crimped a piece of copper tube to the end of the

piece of copper tube to the end of the

piece of copper tube to the end of the wire and secured it to the clamp with

wire and secured it to the clamp with

wire and secured it to the clamp with the screw the spring and the clamp is

the screw the spring and the clamp is

the screw the spring and the clamp is surprisingly powerful it bites down with

surprisingly powerful it bites down with

surprisingly powerful it bites down with a good amount of pressure and that’s

a good amount of pressure and that’s

a good amount of pressure and that’s what we’ll need for making a firm

what we’ll need for making a firm

what we’ll need for making a firm connection with our workpiece now a

connection with our workpiece now a

connection with our workpiece now a welding rod could just be pinched to the

welding rod could just be pinched to the

welding rod could just be pinched to the cable with a pair of pliers but I went

cable with a pair of pliers but I went

cable with a pair of pliers but I went ahead and spent $13 on a proper

ahead and spent $13 on a proper

ahead and spent $13 on a proper electrode holder this makes it look more

electrode holder this makes it look more

electrode holder this makes it look more like a real welder and adds a tremendous

like a real welder and adds a tremendous

like a real welder and adds a tremendous amount of convenience and control okay

amount of convenience and control okay

amount of convenience and control okay we’ve got our lugs crimped on the ends

we’ve got our lugs crimped on the ends

we’ve got our lugs crimped on the ends of the secondary coils so let’s mount

of the secondary coils so let’s mount

of the secondary coils so let’s mount the Transformers on the base you

the Transformers on the base you

the Transformers on the base you probably notice that I cut the cable in

probably notice that I cut the cable in

probably notice that I cut the cable in the middle and crimp them to a common

the middle and crimp them to a common

the middle and crimp them to a common lug in the center this is because I

lug in the center this is because I

lug in the center this is because I wanted the option to Center tap the

wanted the option to Center tap the

wanted the option to Center tap the Transformers to power other devices like

Transformers to power other devices like

Transformers to power other devices like an electrical arc furnace look for how

an electrical arc furnace look for how

an electrical arc furnace look for how to make that in a different project a

to make that in a different project a

to make that in a different project a few screws can be used to hold the

few screws can be used to hold the

few screws can be used to hold the Transformers in place and the ground and

Transformers in place and the ground and

Transformers in place and the ground and clip can be connected by overlapping the

clip can be connected by overlapping the

clip can be connected by overlapping the respective lugs and pinning them down

respective lugs and pinning them down

respective lugs and pinning them down with a screw the electrode holder gets

with a screw the electrode holder gets

with a screw the electrode holder gets attached in the same way and here you

attached in the same way and here you

attached in the same way and here you can see there’s plenty of separation to

can see there’s plenty of separation to

can see there’s plenty of separation to prevent the terminals from shorting out

prevent the terminals from shorting out

prevent the terminals from shorting out alright let’s get ready to rig up the

alright let’s get ready to rig up the

alright let’s get ready to rig up the electrical system this cord was saved

electrical system this cord was saved

electrical system this cord was saved from one of the microwaves we tore apart

from one of the microwaves we tore apart

from one of the microwaves we tore apart and after exposing the three wires

and after exposing the three wires

and after exposing the three wires inside I’m going to cut off the green

inside I’m going to cut off the green

inside I’m going to cut off the green one just to get it out of the way it’s

one just to get it out of the way it’s

one just to get it out of the way it’s not going to be connected to anything

not going to be connected to anything

not going to be connected to anything now here’s the trick to powering the

now here’s the trick to powering the

now here’s the trick to powering the welder 240 volts AC I can’t recommend

welder 240 volts AC I can’t recommend

welder 240 volts AC I can’t recommend this as the safest way to do it but

this as the safest way to do it but

this as the safest way to do it but here’s how I did it with a couple of

here’s how I did it with a couple of

here’s how I did it with a couple of plugs a connector and some 10 gauge wire

plugs a connector and some 10 gauge wire

plugs a connector and some 10 gauge wire each outlet in my house provides around

each outlet in my house provides around

each outlet in my house provides around 120 volts ac and they’re connected to a

120 volts ac and they’re connected to a

120 volts ac and they’re connected to a circuit breaker bus bar there are two

circuit breaker bus bar there are two

circuit breaker bus bar there are two breaker buses and if a hot lead is taken

breaker buses and if a hot lead is taken

breaker buses and if a hot lead is taken from each of the buses we get 240 volts

from each of the buses we get 240 volts

from each of the buses we get 240 volts now rather than tapping into the breaker

now rather than tapping into the breaker

now rather than tapping into the breaker box directly I ran extension cords to

box directly I ran extension cords to

box directly I ran extension cords to two different wall outlets that were a

two different wall outlets that were a

two different wall outlets that were a hundred and eighty degrees out of phase

hundred and eighty degrees out of phase

hundred and eighty degrees out of phase the extension cords connect to this

the extension cords connect to this

the extension cords connect to this adapter which basically just connects

adapter which basically just connects

adapter which basically just connects the two hot leads together if connected

the two hot leads together if connected

the two hot leads together if connected properly the end result is 240 volts

properly the end result is 240 volts

properly the end result is 240 volts looking at the back of the transformers

looking at the back of the transformers

looking at the back of the transformers you can see four terminals that connect

you can see four terminals that connect

you can see four terminals that connect to the primary coils I used some

to the primary coils I used some

to the primary coils I used some salvaged cables and wire nuts to connect

salvaged cables and wire nuts to connect

salvaged cables and wire nuts to connect a hot lead to one transformer and a hot

a hot lead to one transformer and a hot

a hot lead to one transformer and a hot lead to the other another wire was used

lead to the other another wire was used

lead to the other another wire was used to bridge the two connecting them and

to bridge the two connecting them and

to bridge the two connecting them and series by the way the color of these

series by the way the color of these

series by the way the color of these wires doesn’t mean anything they’re all

wires doesn’t mean anything they’re all

wires doesn’t mean anything they’re all going to be shock hazards okay to finish

going to be shock hazards okay to finish

going to be shock hazards okay to finish up let’s fasten the power cable to the

up let’s fasten the power cable to the

up let’s fasten the power cable to the base so it doesn’t pull the connections

base so it doesn’t pull the connections

base so it doesn’t pull the connections apart if the cable gets jerked around

apart if the cable gets jerked around

apart if the cable gets jerked around it’s extremely important to remember the

it’s extremely important to remember the

it’s extremely important to remember the system has no on/off switch it can only

system has no on/off switch it can only

system has no on/off switch it can only be used with a power controller like the

be used with a power controller like the

be used with a power controller like the scary AK you can see how to build this

scary AK you can see how to build this

scary AK you can see how to build this one in another video if you remember

one in another video if you remember

one in another video if you remember back to when we inserted our new

back to when we inserted our new

back to when we inserted our new secondary coils I mentioned it didn’t

secondary coils I mentioned it didn’t

secondary coils I mentioned it didn’t really matter which way they went in and

really matter which way they went in and

really matter which way they went in and here’s why when the power is on and our

here’s why when the power is on and our

here’s why when the power is on and our welding electrodes are connected to a

welding electrodes are connected to a

welding electrodes are connected to a multimeter we should expect to see

multimeter we should expect to see

multimeter we should expect to see around 36 volts but here we’re only

around 36 volts but here we’re only

around 36 volts but here we’re only getting 2.4 that means the Transformers

getting 2.4 that means the Transformers

getting 2.4 that means the Transformers are canceling each other out

are canceling each other out

are canceling each other out to fix this problem let’s just turn off

to fix this problem let’s just turn off

to fix this problem let’s just turn off the power and remove the connections to

the power and remove the connections to

the power and remove the connections to one of the Transformers it shouldn’t

one of the Transformers it shouldn’t

one of the Transformers it shouldn’t really matter which one then we simply

really matter which one then we simply

really matter which one then we simply switch the connections around that’s it

switch the connections around that’s it

switch the connections around that’s it this time when we turn on the power and

this time when we turn on the power and

this time when we turn on the power and check the voltage we’ve got 37 volts now

check the voltage we’ve got 37 volts now

check the voltage we’ve got 37 volts now rather than leaving all the dangerous

rather than leaving all the dangerous

rather than leaving all the dangerous components exposed I think we can build

components exposed I think we can build

components exposed I think we can build a makeshift casing from this plastic

a makeshift casing from this plastic

a makeshift casing from this plastic container here are the exact

container here are the exact

container here are the exact measurements if you care to know I chose

measurements if you care to know I chose

measurements if you care to know I chose to use the lid as a base and use a

to use the lid as a base and use a

to use the lid as a base and use a rotary tool with a cutting wheel to make

rotary tool with a cutting wheel to make

rotary tool with a cutting wheel to make the surface flat our entire welding

the surface flat our entire welding

the surface flat our entire welding assembly should fit right in the center

assembly should fit right in the center

assembly should fit right in the center without any problems I gave the whole

without any problems I gave the whole

without any problems I gave the whole container a paint job set the bin into

container a paint job set the bin into

container a paint job set the bin into position and locked it into place two

position and locked it into place two

position and locked it into place two holes went in the front for our

holes went in the front for our

holes went in the front for our electrode cables and I also cut some

electrode cables and I also cut some

electrode cables and I also cut some ventilation holes on the sides there’s a

ventilation holes on the sides there’s a

ventilation holes on the sides there’s a hole in the back for the power cable and

hole in the back for the power cable and

hole in the back for the power cable and now our welder is completely finished

now our welder is completely finished

now our welder is completely finished and ready to test

and ready to test

and ready to test let’s start by directly shorting out the

let’s start by directly shorting out the

let’s start by directly shorting out the ground clip with the electrode holder

ground clip with the electrode holder

ground clip with the electrode holder because this will allow the maximum

because this will allow the maximum

because this will allow the maximum amount of current to flow we’ll use an

amount of current to flow we’ll use an

amount of current to flow we’ll use an amp meter to monitor the primary current

amp meter to monitor the primary current

amp meter to monitor the primary current turn on the scary AK and

turn on the scary AK and

turn on the scary AK and power up when the power settles at

power up when the power settles at

power up when the power settles at around 15 and a half amps on the primary

around 15 and a half amps on the primary

around 15 and a half amps on the primary you can see it produces about a hundred

you can see it produces about a hundred

you can see it produces about a hundred amps on the secondary the average is

amps on the secondary the average is

amps on the secondary the average is adjustable so if we add more power we

adjustable so if we add more power we

adjustable so if we add more power we can jump the weld and cables to over 200

can jump the weld and cables to over 200

can jump the weld and cables to over 200 amps in any case there’s certainly

amps in any case there’s certainly

amps in any case there’s certainly enough power available to strike an arc

enough power available to strike an arc

enough power available to strike an arc sustain it and weld some metal you can

sustain it and weld some metal you can

sustain it and weld some metal you can see some of my first few experiences

see some of my first few experiences

see some of my first few experiences with the world of welding in another

with the world of welding in another

with the world of welding in another video well that’s it for now if you like

video well that’s it for now if you like

video well that’s it for now if you like 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]