How to Turn Your Alternator into an Arc Welder

[@sweeneyoffroad]

If anyone is interested I have a video breaking down this mod step by step. Thanks Merlin for the diagram! I made a slight modification from yours as I added an external rectifier. I believe that will avoid the burnt diode that your alternator experienced.

[@MrMrsregor]

yes ! i saw your video a few days ago, very well done! thank you for filming and uploading it for us

[@mattc3368]

I dont know if Merlin was a teacher at 1 point in his life if not he'd make 1 helluva teacher! Thanks for the videos you're a cool dude.

[@randytravis3998]

I think we might have to call him MR Merlin if he is going to be a teacher

[@scubasteve7946]

Lol one of those cool teachers that the one wise arse kid lipped off to one time at the start of the school year. And that's the only time it takes for everyone else to learn not to do that again 😂

[@electrontube]

it's pretty intuitive if you think about it. Alternating Current changes direction intermittently. Direct Current moves only in one direction. A good way to remember it: a rectifier converts to DC, an inverter converts to AC. Diodes only allow current to travel in one direction. They're solid-state, no moving parts. Rectifiers are simply just diodes in series to handle the strength of a load. Which is why you can get away with stick welding, it doesn't need a smooth (clean power) sine wave like in AC welders. Stick welding just needs power. I'd recommend 6010 with some practice at home before you pack it for emergency trail fixes. My preference is 1/8" Fleetweld 5P+ rods.

[@slowcountryboy476]

sooo Jimmy is kinda dim?? Kinda like someone I know, I am always wanting to learn new stuff. The reason I happened upon this video is because I was looking for the Premier Welder and a couple of other videos like this popped up. I would like to set up an auxiliary alternator just for welding. My idea includes having a machine shop add and balance a pulley to the existing alternator to run the welder alternator to keep the two isolated from each other. What do you opine??

[@perrymattes4285]

Just some things to add to this. There are two flavours of alternator delta and y. Delta are better at producing current You really need a control on your rotor. To control the voltage. Stick weld is not constant voltage but constant current. There is a circuit on line that varies the rotor voltage to keep the output current constant. The other thing is to use reactance on the out put cable. Just the weld cable rapped around a pipe. This will stabilize the arc by building a magnetic field if the arc breaks the magnetic field collapses and the high voltage will re light the arc. Lastly newer alternator diodes are made to blow with more than 40ish volts to protect the ecu in a car. Use an old bosh they are rated for full current and are delta wound. I’ve done this same thing and learned a lot Good luck.

[@kalaehina814]

Merlin and Jimmy are becoming my favorite Sunday morning duo 😂

[@carrollsanders9376]

Had a buddy that had an Alternator welder run off an old Homelite Chainsaw, worked fine and a lot better than goofing up a vehicle. He used a rheostat too control the Imput too the Alternator rotor though the brushes, this is actually a 40 year old trick.

[@calholli]

I wish you would do one more follow up video here that's focused on how to run your "Welder alternator" like a regular welder again, with the external regulator and how to hook it all up correctly and how it should work, what all the wires do, etc.. That would be a perfect sister video to this one. I really appreciate you teaching this stuff, because most people like to keep these types of things their little secret. cheers.

[@MerlinsOldSchoolGarage]

Print the diagram it’s all there

[@calholli]

@@MerlinsOldSchoolGarage There's just a lot of wires on the regulator, and I'm not sure what they all do. Also, does the external regulator have it's own diode set? Or are you still using the internal diodes of the Alternator? I can see, and do understand that schematic-- I'm just not so sure about the exact parts. (I can figure it out, I'll just have to watch a few more vids.) Cheers.

[@neilfromclearwaterfl81]

@@calholli You bypass the internal regulator accessing/exciting the brushes/stator directly with the external regulator. This can get tricky on some of the newer alternators with an integrated regulator/brush holder assembly. On some you may have to do a bit of de-soldering and cutting to bypass the internal regulator plus be careful of those where the fields are bolted to the front half of the alternator casing and soldered to the rectifier, etc bolted to the back half or you'll end up having to replace/repair the field coil. Watch out for newer vehicles that have no traditional voltage regulator since some for fuel economy, emissions and such have the alternator regulated by the Engine Control Module. On those you need to take steps to keep that computer happy and not reading a charging system fault at all times or perish the thought end up damaging a $1,000/$2,000 ECM. Best

[@calholli]

@@neilfromclearwaterfl81 That's what I wish he would show, is how he likes to connect to the brushes and all the little tricks to make it work right. I guess I can just look up videos on people rebuilding alternators and learn more that way. Thanks..

[@neilfromclearwaterfl81]

@@calholli He showed the connections for the make and model of alternators he was working with at 1 minutes 5 seconds, 12 minutes 45 seconds and 18 minutes 35 seconds in the video however there are too many differences to be able to show them all so you have to look over the one your currently working with and make accommodations based on what your have in front of you. Some will have screw terminals, others spades while others will require some cutting and soldering. Unfortunately there's no one or two solutions. Some alternators will not be as easy to convert as the two specific ones he recommended.

[@waynefields4813]

Always enjoy learning new things, don’t let age stop you from growing, I’m 65 and love learning new things

[@ebikeliverystable]

I was introduced to this method of welder from my mentor at a very young age. He told a Korean war reconnaissance mission for returning a crippled tank. It had suffered a broken axle so he welded it up for it to be loaded on the truck. He also used a pickle crock to boost amperage and a set of jumper cables to finish the task. Thanks for sharing

[@allynshadowens8116]

I worked at an alternator shop 30 years ago and built one for my landcruiser. I used the big case ford off an off a LTD. They hold up better. Bigger heat sink. Worked great!

[@mistersniffer6838]

Dude at autozone will not know "big case mid 80's ford alternator please". What year and engine?

[@mobilemowers]

I'd say 1975 - 1977 LTD with 460 else 400. Look at them and should be able to tell which is bigger.

[@j_rainsgoat3929]

​@@mistersniffer6838 yeah but you'll get a lifetime warranty at AutoZone

[@johne189]

The "Big Ford" is sometimes called a Side Terminal Ford. For just a boring old Big Ford story read further. About 40 years ago I was involved in test-to-failure to see which of the then readily available automobile alternators would be most suitable for repurposing similar to this welder build. For the tests alternators were mounted to a SERIOUS test bench and ran full-field with carbon-pile high load for all they were worth. I don't recall exactly, but it seems like about 90 volts and 10 minutes would eliminate most contenders; usually with a smoke show. LoL The Big Ford we got tired of listening to it scream for more after already having burned up about three drive belts.

[@WhiteHorse4x4]

I sure would like to see a full install video from start to finish.

[@madcapmagician6018]

i did not realize your diagram shows how to not only turn your alternator into a welder, but still use it to charge the vehicle... that was pretty cool =)

[@markdoyle9642]

I am a retired physicist who grew up in Eastern Oregon. My dad, and other WW2/Vietnam Veterans, taught us how to use electricity from the resources available, just as you describe, but in order to survive. My brothers and I were often Stuck, far into the woods, but made it home by understanding the incredible power connected to a piston engine via. generator or alternator, as Our Veterans needed to survive. You explained this PERFECTLY, RESPECT for the ingenuity of neccesitty! Dribbling gas through the valve stem to reinflate our tires was a very bad idea...but it worked 'Just Say'n (Huge Smile)

[@Hootman865]

I bet you could go hundreds of how to videos. Thanks Merlin, going through my alternator’s right now.

[@seanworkman431]

With a simple explanation the idea of approaching that myself is doable rather than daunting, thank you.

[@kalaehina814]

Wish my auto shop teacher was as easy to understand as you are. Great video Merlin!

[@donlarsen9807]

Maybe your shop teacher didn't have the knowledge that you see on this channel

[@kalaehina814]

@@donlarsen9807 👍Possibly 😁

[@psg6314]

Great video and great example of how to get it done I put one alternator on my truck for charging the battery and one for welding God bless from GA and stay safe

[@scottyh72]

Did this over 30 years ago. Taught myself to weld with the set up. Even repaired and got people out of the woods with it.

[@MerlinsOldSchoolGarage]

that is awsome

[@CurtisDrew1]

Me too. Built one on my 93 Isuzu Rodeo and made many trail fixes to Other Guys Rigs. Eventually replaced the small alternator with a 250 AMP one and need to hool my welder stuff back up.

[@lisaharvey4373]

Very educational video Merlin, I had a conversation with my coworkers about how people were doing trail repairs using their alternator to arc weld with just a couple modifications to their alternator, they just couldn't believe it so now I will share your video with them, then they will finally get it.

[@oldolfmann8927]

OMG... LOL... Safety at it's finest. Not to mention welding while work piece is clamped to a plastic milk crate. Holding work piece in mid air while my buddy grinds it and shoots sparks into my eyes. Love it

[@larryisreal8150]

Over 30 yrs welding and I'm impressed. Thank you sir!

[@michaeltablet8577]

Excellent video as always!! Reminds me of my childhood watching my Dad weld a muffler on his 53 International pickup on the side of the road with jumper cables and a coat hanger. Please keep making videos and pass on your skills and wisdom to future generations. God bless you and yours!

[@matthewyanta4217]

I did this to my 96 dodge 5.9 cummins. Welds great! Awesome tool to have on the trail. Thanks for the inspiration!

[@bigds6692]

Oh yeah! A bunch of us will be welding on the trail thanks to you!

[@calholli]

He asked about the phases: (I can't draw a sign wave, so I'll just use 'n and u") When you stick a single phase through the rectifier, it turns all of the negative AC pulses into another positive pulse; so then your signal likes like this: From AC= n u n u n u n u To rectified = n n n n n n When you have more phases, it will do the same things, but just at a slightly shifted time frame, and make the signal look like this: Single phase rectified= n n n n n n n n Only two phases rect. = nn nn nn nn nn nn nn nn Three phase rectified = nnnnnnnnnnnnnnnnnnn So it's the same things happening, there are just three of them happening slightly ahead of one another in time, which fills in the gaps between each pulse. Giving you a higher resolution of pulses, basically turning it into nearly a smooth DC voltage.. They could even put more phases and it would smooth it out even more, but that costs more money and isn't necessary, because 3 phases already smooths it out quite a bit... Very cool stuff-- I learned a lot here and I'll be building one. Cheers.

[@79tazman]

That is cool I have welded with 12 volt batteries before but never with a alternator I got to say that is cool. Man you can have a alternator for a welder and turn a A/C compressor into a air compressor you can have a whole service rig running off your engine.

[@robhart6042]

I followed Paul Cox's Fab Rats videos here to Merlin's (Paul's Uncle, I think) - I have enjoyed seeing Merlin all around the Southwest Utah's rock crawler community - and I must say (as others have commented here), if Merlin has not been an actual Teacher, he surely IS a really Good one. Thank you so much Merlin - wish I had moved out of northeast Maine and gone out there to meet you guys a long time ago (most particularly about 1997-1998). I have done mechanics work beginning when I was a little boy - taking toys and other stuff apart - then on my own cars - a 'little' fabrication related clunker overhauling all my driving years, and absolutely fell in love with this whole realm of both off-road driving adventure and most of all Building Stuff, including from junk automobiles and scavenged & improvised materials. I am a Tools Addict - just can't help myself, ha-ha. Oh, not to mention that the Gorgeous land and climate out there are simply Luscious (no long, hard winters).

[@almclean4835]

I looked at vehicle mounted welder after seeing fabrats had one. Your way appears to be as good a welder but way cheaper, for me cheaper is good as it’s something I’d use but not a lot. Thanks for sharing it Merlin👏👏

[@electrontube]

Legit. Such a good piece of information, and a very good way to get concepts across to your audience. You use a first-person POV (real-time, from Jimmy) to make it happen. So good.

[@shanesdiy]

I found a kit with everything you need to convert an alternator like that about 25 years ago. Never installed it, still out in the garage right now. lol. Super cool device, thanks for reminding me of this!

[@garywetzel8240]

My X Father-in-law over 40 Plus year's ago built these to run off your vehicle. Sold thousands of these throughout the United States. Pretty cool concept

[@rcman75]

That was a incredible video my father was an electrician and in his old 1966 GMC K 2500 he had an outlet for running AC power tools very similar to what you just showed us minus the welder. Keep up your awesome content absolutely love you channel, Thank You for what you do on You Tube 👍

[@haydenperrine854]

Well that explains the "86 f-350 I bought from a SoCal Edison auction. With a flip of a switch on the dash, I could make the Mr. Coffee maker work that had been mounted on the hump in front of the seat and the 115 vac receptacle on the utility box for my 4" grinder worked, with no fancy aftermarket inverter.

[@l0l0mgwtgdq]

@@haydenperrine854 the rectifier inside the alternator is the same as an interter. it uses a diode to turn a AC sign wave into a DC square wave. 120v would be 12v DC rectified, etc

[@andreblanchard8315]

I have done this with a tractor to have a portable welder. I added a second alternator, leaving the first to keep the battery at a full 14 volts. Then I put a big rheostat in series with the welding alternator field to fine tune the heat. Nice thing with a tractor is the engine speed is controlled by a governor, so is more constant. Found a Lincoln weld pak 90 with a bad transformer or diodes, wire feed still worked. Connected it up to the welding alternator and a small inverter to run the feed motor and could do flux core wire welding with 100 percent duty cycle instead of 10 percent for the stock Lincoln. The cheap gun would get hot after a while.

[@terrywitbeck3755]

Just reading some of the other comments. I’m thinking that I would never be in a situation where I need a welder out in the wild. I’m also thinking that the welders Paul and Rory use are just commercial versions of what you taught us about in today’s video. DIY is my normal MO. Thanks for the info.

[@jeffg4008]

Amazing. Now let's see how you setup those cheap air conditioner systems in your vehicles you've talked about. Great stuff!

[@phillipdewitt4454]

Looking forward to trying that.

[@randytravis3998]

a system that makes air . so you can run air tools / tires

[@LarsDennert]

Nice post! In a pinch I've welded with 3 car batteries in series. Simply use 2 sets of just jumper cables. You'll end up with two nice clamps left over. Wire for positive ground, a piece of welding glass and some 6014 sticks. Modulate the power with the angle of the stick. I've successfully repaired motor mounts and idler arms.

[@chriscoulthard4947]

That's what BSF did at the games

[@JohnnyQuest1960]

We had a alternator welder in the 80's it worked great.

[@ryehammer4793]

You are a wealth of knowledge and appreciate your information sharing and teaching. You clearly explain the workings, required changes and execution. 👍🇨🇦

[@brucegarrett7232]

Great information. Instructions are spot on. Understood the diagrams all the way. Bring more of these videos.

[@eck8240]

Thank you sir you're a scholar and a gentleman and ignore everything else I say about you you're a good guy I think God bless you

[@byronlabelle7569]

That was a fantastic lesson and something to have even if you don't go 4 wheeling. Thanks to all of you for sharing this with your subscribers & viewers.

[@lonhoschar1943]

Great video Merlin!! A lot of us dyi ers love this kind of stuff! Not sure I'll ever use this particular method but it's nice to have in the cupboard for "in case". Thank you for teaching this kind of thing!!!

[@desertd2609]

Awesome vid! I remember reading up on this welder set up years ago in 4wheel mags but never did one and have since thrown out 38years of my mag collection. I will be printing off what you gave us to print and utilizing it this time!

[@scubasteve7946]

See, I told you you would need to look back and read them for something at some point!!!

[@johnperun232]

Thanks again for all of your content Have a Great Day 👍 God Bless You and God Bless America 🇺🇸🇺🇸🇺🇸🙏

[@theodoredugranrut8201]

That is cool, my dad's work truck had a welding alternater called high frequency. Instead of using high voltage to make heat it used higher wave frequency. Thanks Merlin Central California watching

[@CCerwin]

Its very cool 😎 seeing what is old technology being explained by a great teacher. Pay attention to people with this type of mind bc you will learn much!

[@kregstory9232]

Very good job. Nice teaching basics and to set up a welder on the rig u go off road in. Stay safe.

[@OwensGarage]

This is the coolest thing! I wanted to put premier power welders on my jeep and my truck but really didn't want to spend the money... now I'm gonna go do this to all my vehicles, because why not?

[@krisquibodeaux3971]

After seeing this video, I’m thinking about putting a dual alternator setup on my truck. One for charging and one for welding and as a backup for the first alternator. By doing that, I would essentially have a backup alternator if my primary ever went out and I wouldn’t be worried about stressing my primary alternator from welding. I may take it a little further and put a voltage and frequency monitor on it to regulate for grinders and stuff like that. A friend owns a generator shop and we could probably come up with a way to put a generator style voltage regulator in the mix to provide “clean” ac power to charge power tools.

[@Mr2eyedjack]

My welding instructor in HS has an old international truck, he had 2 altanator one for the truck the other was the welder I think. We all got to try using and he took us out to a farm to weld on some farming implements.

[@g0fvt]

Fascinating video, I built an external regulator for a friend's car years ago to save him the cost of buying a new alternator (it was a weird one with a vacuum pump on the back of it). The regulator itself is super simple circuit with just 2 transistors and a few other components. Watching your video I realise I could have done so much more with it. I was going to attach a car alternator to a lawnmower engine for charging car and boat batteries but making it into a welder as well would be really useful. Thank you for posting the video, you have given me a few ideas.

[@troyboy9308]

I remember about 30+ years ago my father did that to his truck, you plugged the welder in a connector in the grill also had a receptical there to plug in 120.

[@scottmoody3926]

I like to learn something new every weekend. This might be the most useful so far. Thank,you.

[@williamlind2843]

Awesome job!! Now I have another project!! Thanks a lot!!

[@stumped463]

Just like Jimmy said that's the coolest thing I've ever seen . Great video thanks .

[@CNCmachiningisfun]

I have done this for the past 22 years, and the alternators really do stand up to the load amazingly well. My rig was able to supply a steady 240A, while delivering 9KW into the welding electrode, at 100% duty cycle. Today's alternators are OK, but their diode packs are not rated for the higher voltages, so external ones should be fitted, for long term reliability.

[@mistersniffer6838]

Well, what did you use??

[@CNCmachiningisfun]

@@mistersniffer6838 I used 6 alternators from the 1980s, taken from Ford Telstar cars. Each one was rated at 60 amps, which I also measured, and confirmed to be the case. 4 were always active, and the other 2 were there as backups, hence the 240A rating of the machine. Those older alternators can easily handle 120V DC, whereas today's ones will burn out their rectifiers, by the time they get to a mere 30V DC.

[@mistersniffer6838]

@@CNCmachiningisfun - Thank you

[@CNCmachiningisfun]

@@mistersniffer6838 You are welcome :) .

[@nikspanakis]

They're using shottky diodes for lower forward voltage and fast recovery that leads to higer efficiency but they are lousy at high voltages. An external rectifier pack is the way to go. An if you're into electronics you can make a simple circuit to control the current by varying the exciting voltage. Electrodes need mostly constant current. Cheers.

[@j.j.clingman4083]

Merlin I’ve been actually thinking about getting one of those on board welder setups but was kinda not wanting to spend the money on one quite yet!!! I’m definitely glad that I waited and seen how you do them!!! I’ll definitely be trying to make myself a setup for my 1981 Chevy 1Ton 4x4 that way when one of my buddies breaks down on the trail and is wanting to call a wrecker to have it hauled back to the shop for a repair I will be able to just do it out on the trail!!! Awesome video buddy!!! Hopefully I can figure it all out and get it figured out Wright!!! Lol!!! Well thanks again and remember keep up all the hard work buddy!!!!

[@OwensGarage]

same here! I'm gonna build one for my XJ and my first gen Dodge.

[@thesalopgardener]

That's bloody fantastic fella. Great tutorial, really easy to follow.

[@levergun]

EXCELLENT video, Merlin. Fun and educational plus the coolest golf cart on the planet. Thanks for doing this!!!

[@familiaUrrutiaJourney.official]

Hi, I really enjoyed the video, but it's there that you could do a video following your schematics and assembling the alternator dummy style 😊.

[@ramirohernandez2052]

Wow, that is an amazing set up, but only the Savvy smart cool guys who actually work with their hands. Very nice thanks

[@colintanner8744]

Merlin the Magician comes through again ! Thanks for the tutorial. Outstanding.

[@spc.callahan1462]

Nice walk thru, I made one of these for my 87 Suzuki Samurai out of the 60amp Delco 10si. I made one for my buddy out of a Ford top post alternator. Good old "Weldenator."

[@Chris-lp3dm]

Excellent video. The only thing that threw me a bit is you called a Double Pole Double Throw switch a "six pole". So I was staring at your diagram trying to figure out the other four poles when I realized you are counting all the connections on the switch as a poles.

[@Junk_Yard_Dog]

Excellent video and description with one flaw. The switch is a double pole, double throw. Not a six pole. Keep up the good work.

[@MerlinsOldSchoolGarage]

yes you are right

[@rmeav8er677]

That makes it much easier for trail repairs instead of having to buy the vehicle welder that Paul uses. Much cheaper too.

[@krpaintingandhomeimproveme307]

1 HELL OF A VIDEO AND EVEN BETTER TEACHING ! You've knocked this outta the park, Fella !! Thank You for sharing buddy

[@slipstream5542]

That was amazing thanks Merlin 👍🏼 that weld came out really nice

[@jeffpreskitt741]

This video alone is worth a million subs man!!! 👊

[@joshuabennett7334]

I would be interested in building one and taking a single cylinder Briggs engine to drive it. Have a gas powered portable welder made out of scrap instead of paying a couple grand for one

[@MrGrimCarnage]

Just making sure I'm reading the schematic correctly.......the relay is to isolate the alternator from the vehicle when you apply full 12V to the field winding (basically disconnecting the 120V from the rest of the vehicle systems so you don't fry everything). If a second alternator is used, the relay and regulator can be eliminated, and a simple single pole switch used to supply an on/off 12V field signal, correct?

[@MerlinsOldSchoolGarage]

yes

[@rockytho1354]

@@MerlinsOldSchoolGarage do you have a part number for the relay? its not listed in the parts list above.

[@Paiadakine]

I built one for my jeep using a stock dodge 1990 alternator. Externally regulated so no modifications. I can also run a 4 inch grinder. Made it to fix out on the trail. But also built a 12 foot metal gate frame. The sound is unique too.

[@MerlinsOldSchoolGarage]

Awsome 😊🏁

[@ponypwr]

Thanks for sharing your knowledge with us old school is the only school!

[@theodorenickel7462]

Thank you for sharing this. I have heard of it but never saw the schematic. You have done the DIY guys a big favor here. Thank you so much.

[@k5rmj]

I always thought you could do that, now I'm going to build it. Thank You

[@ionstorm66]

If you want an even better setup: Go on ebay and buy a 110-220v input inverter stick welder. Pop it open, and find the input rectifier. Flip 2 of the diodes so its just straight DC input. Get a pair of anderseon connectors, and set it up so you can plug the welding output from the setup in the video into the welder with the correct polarity. Now you can use current control with this setup. You can even use a multi process machine. I have a 200A alternator feeding into a $100 160A multiprocess welder. Welds just like a shop machine. Dose stick/tig/mig like butter. Should work for AC inverter machines do for aluminum. You can even get a plasma running this way if you could get dry enough air.

[@assyholey4224]

WOW we were doing it in the 1940's

[@sweeneyoffroad]

Hey @HotelSoap, do you mind me getting some contact info so I can ask you some more questions about this? I’m making a video on how to do this but I’m running into some annoying problems

[@dixiemae5042]

Yes. See the light on above his head already 👍🏻👍🏻

[@danielnicholls6868]

seen a lawnmower belt out of chute to run alternator and a battery to stabilize current in old magazine

[@michaelgile5749]

Thanks Merlin! Awesome video, great for those trail repairs, helpful and complete, full of detail and very understandable, now I just have to get off my but and do mine!

[@fredkidd3720]

Merlin, you really are a wizard! Thanks for the lesson!

[@luemn7691]

I know you learn something new everyday but dang this is worth more than the things learned in the past week! Thank you for sharing. From my view it looks like you are living the dream.

[@SolbiatiMiguel]

absolutely great guys, this can be a solution to repair the car in a remote area and being able to return home. My best regards from Italy !!!!

[@markg3305]

Am I the only one that immediately squints when they see an arc strike even on video..? 🤣

[@mickbaker2483]

This a fantastic idea Merlin I'm going to give this a go I'll print your diagrams off to keep thanks bud.

[@kevinfisher619]

I run my own shop on the side. I would love to come learn from you for a week. You are a wealth of knowledge.

[@demonic477]

back in the 80's we used the 100 amp Lincoln continental alternators and the big dodge 90 amp alternators to make welders . we also took the air conditioner compressors out of the dodges to make air compressors the old dual head dodge compressors worked great as air compressors and lasted for ever . we also used alternators to make power generator's for wind mill power poles back in the 70's and 80's so If you lived in the woods you could still get 120 volt power . it's an old farmer trick from the 20's and 30's but it still works

[@michaellodge5456]

I'm not a welder but pretty cool explanation on how that works thanks 👍. I believe Rory has a welder setup similar to what you have on Trail Mater

[@mikefanick6522]

Even sounded the same with that high pitched squeal. I believe Rory said something about having to use a brush type tool for it to work on his machine.

[@dougpersell8776]

Very interesting . I built a welder with a air craft generator it worked good but couldnt be turned down very low. I will be rigging a alternator up soon . Thanks for showing how. I have been watching your videos and wondered just what kind of guy you are. This video makes me think your a good guy that knows his stuff thanks.

[@assyholey4224]

1942 or before aircraft generator. welding this is not new

[@dougpersell8776]

@@assyholey4224 If its something from the 40s it wouldnt be new but there are not alot of people alive that has built one.

[@LimestoneCoastCustoms]

When I fitted my 2nd alternator I thought about doing this (I have reasonably high power demands especially at idle, hence the 2nd alternator) but I never got around to figure it out. You've given my the inspiration to go ahead & see if I think i can do it now. The 2nd alternator would of course still allow for some 12volt charge when it's switched over to welding. As I have also installed an engine driven air compressor, tank & hose reel I also want to put on some form of throttle control, so it too would double for welding. Now just to figure it all out. Thanks! oh! Mine is single wire GM

[@maddad78]

Thank you for the education and knowledge, Merlin. In this life I try to learn at least one new something everyday, you just took me to school.

[@socaliguy81]

As a car audio guy, I would just add a second alternator solely for welding using a custom bracket. If you put a manual locking clutch on the pulley, you could easily turn the 2nd alternator on /off. I wouldn't feel comfortable putting my only alternator through this kind of torture for fear of damaging it.

[@Steve-od6hi]

How cool is that? Should I have one converted alternator and one for normal use on the engine? Will a six HP gas lawn mower engine drive a modded alterbator?

[@staglione79]

Good stuff Merlin, thank you for sharing your knowledge 👍🏻👍🏻👍🏻

[@MaxNafeHorsemanship]

Simple enough. Now I know how my dad's car worked. Back in the 70s he bought a kit to go under the hood of his car so he could power his drill etc. If only I had known I could have welded with it. Maybe add a volt meter to it. I know how to vary a regulator. Dodge has fewer wires. The possibilities. I got ideas now. This also explains how the rather expensive kits work that make welders for off road work. This is way cheaper and so simple there is no need to ever buy one of those overpriced kits. Thanks!

[@rayadams5076]

In the immortal words of Mr. Spock; Fascinating. Thanks for the video.

[@keithnoneya]

Love this video, I'll have to try this on my F350. With that said as an electronics technician fixing Military Aircraft and Aircraft Test Sets and have worked with and on Million Dollar computer controlled Test Sets for the last 42.5 years. The example of the Rectifier Circuit explanation is correct, EXCEPT Electrons the Negative part of electricity, the dots in the video, are moving in the wrong direction, LOL. They always move toward the dash on the diode Arrows, which is the Negative side on the diodes. What the author of the video probably meant to say is the "Electron Holes" or lack of electrons which is the (Positive Voltage) moves only in one direction, or with the arrow direction on the diodes as that is shown in the video. For the video to be correct he needs to use the term "Electrons Holes" or "Positive Voltage". "Simply Electronics" got the terminology, Electrons vs Electron Holes (Positive Voltage), wrong on this one. I see this error A LOT in electronics video's explaining how a Rectifier works, other than that his theory is correct on how it works. If you'd like to see how diodes actually work check out this video; kzbin.info/www/bejne/omPcXqpvlrhsbs0. Thanks for sharing, Loved it. Best Wishes & Blessings. Keith Noneya

[@frankiesaotoandmore5872]

That's awesome thank you Merlin that was a really big help I love the way you broke it down with the wire and diagram and everything can you do one on converting an AC compressor to an air compressor

[@oursxsadventures8156]

Thanks. I've been looking forward to this since you mentioned it. I'm going to do this to my Ford after Snowbird season.

[@michaelsmith-0744]

When worked generator 1500 rpm =to 50hz,and 1800 RPM =60hz , most welder 13 hz-100hz thanks great video make think!!!

[@reddye2331]

KZbin--Best out there hands down! Still waiting on a follow-up/check in on WES’S truck build

[@davedegan12]

Great video. Be adding one to my cj3a with a gm alt. I was thinking of adding a switch in the stinger to start and stop the field voltage. Help to keep the alternator cool.

[@michaelcheslock7866]

Finally explained so I can understand!!!!