miller thunderbolt ac review and slight repair with dielectric grease

[@mh1art870]

I just finished cleaning up my 1978 miller thunder bolt. It’s amazing works great.

[@ManVsOven]

My father bought his new around 1977. It still works great… but I need to lube my internals too, thanks for showing how-to

[@swiss6253]

Got mine for $100 too. Mine is a rebadged version for a hardware store that used to be in Ohio called Anderson's. It's an HD-6, but hard to find much information about it. Pretty cool because it's red instead of blue.

[@thewanderingrays5131]

That’s cool I’d love to see it I bet it’s smooth running a bead

[@swiss6253]

@@thewanderingrays5131 Not sure if I can reply with a link, youtube weird sometimes. i.postimg.cc/V1bv0XQr/rebadge.jpg The crank on the top was broken off, will just use a junker ratchet and socket to turn it. Hoping to finish installing my 6-50r this weekend, haven't had a chance to use it.

[@adnacraigo6590]

I believe that sliding yoke is part of a system known as a saturable reactor. They use that instead of a multiple tapped transformer like the Lincoln buzz boxes. The Miller design has more infinite control.

[@thewanderingrays5131]

I'm not sure about that but if you are I'll go with that lol I do know it's a very smooth welder I love the old thing

[@StonemanRocks]

You can definitely get all the amps you need for about anything I would need for sure to build or repair anything for personal /general shop stuff! Personally I love my miller! After i convert it to dc i think ill like it even better! It burns plenty hot for sure to get most anything done Ive run across!

[@austinmullett430]

I just picked one up and I already love it I only paid 75 for mine but didn't have any leads with it

[@thewanderingrays5131]

Bro white lithium grease man all you need great welders

[@StonemanRocks]

I saw a vid on a guy who went to a junk yard and got the battery cable off some mercedes that had the battery in the trunk! It was a heavy guage cable that was 25ft long because it wrapped around this and that to make it from the trunk to the engine compartment! It cost him only a few bux too like $10 something rediculous! He added the rest from some old leads and boom! Im going to look into it the next time i change mine or want to add length!

[@jafinch78]

@@StonemanRocks I'll have to keep that in mind. Get's me thinking the hybrid cars have some beefy wire too.

[@StonemanRocks]

@@jafinch78 true that! Do you have a you pullit where you live? Elec vehicles probably would have the best plus I think since its vehicle related they probably require it to be overated so ya good idea!

[@jafinch78]

@@StonemanRocks Yes sir, first place I go. I just came back to note that I updated the linked video with more links and the 4th video of that series with links in the description as well. Now, with the pick your parts we have around, I always go to that one. I have a YT video where I just got two tires for an awesome price for the Prius. Speaking of that, let me tell you when they had the 50% off sale I went nuts and got three of the gen 3 Prius Inverter/Converters thinking I can make a welder with one, use one for a future hybrid project in my truck and another one since seemed like why not for $30 along with the wire. Always get the whole section of parts... they charge more if you nit pick little parts out. I also got a CVT with the two Motor Generators that are like ~20KW each I think since was thinking I can make a nice 3-phase generator with one of those and maybe use the second one as a motor for something too. For $70 I was like... that'd be crazy to pass up that huge of a generator. Bummer the 1.8L engines went crazy sky high in price unlike the 1.5L, and I passed on two engines I could have gotten for the upullit price of like ~$300. Oh, well, haven't seen any in since. Yeah, Pick Your Parts they call em here are the best price for certain. There's a place that you can't pick that's local as well that they're only about $20 or so more and they already pull... so I like there too. They're the one that told me to ask for the whole assembly when I needed an inner tie rod. He was like... ask for the whole assembly and I can sell you that for a good price, $50 and that came with both outer tie rods and in. Same price new and they don't sell the inner tie rods for the prius's. Though the outers are $50 for the OEM. Wound up using the same logic at the pick you part to get better deals on those inverter/converters since the first one I paid more since like an idiot I cut the wires to about 6". Best to leave em all connected like I did on the later and those were the best priced... go figure. 🙂 You have a good one and be safe.

[@StonemanRocks]

I got mine for $50 with leads! I taught myself to weld with it although i use the term “weld” lightly the first cpl of yrs! Ive gotten much betterLol! Im in the process to convert to dc . I have the diodes and the rectifier made from a microwave transformer. Not too many vids ive found on doing the conversion that are crystal clear and that have good pics of the wiring! I just want to make sure everything is hooked up right before I hit the switch and fry something! Lol may sound funny but its not funny to myself as im not a trained electrician! I can usually get it done though and do and im not quitting even if i get it wrong the first time! I think it should be fine but I really want to run it by someone with a bigger welding / electrician brain than mine! Going to use your vid as it shows how the orig wiring is hooked up! Thx for posting!

[@thewanderingrays5131]

ok cool keep me posted on that

[@ManVsOven]

The microwave diodes might be high voltage low current. I think eBay has the ones you need, I saw a KZbin on how to do it… and I’m going to add DC to mine too

[@codyoppewal6327]

I have one of these an it works so well, fan is a bit noisy but cant complain.

[@kaseycasece1340]

go by computor store pick up computar fan around $ 14.00 to $20.00 or grease the fan

[@thewanderingrays5131]

lithium grease or die electric grease

[@jafinch78]

Neat too, is how cost effectively these can be upgraded with just a heat sink and rectifier rated for the current and then some. Can also add an inductor coil for smoothing more the current (even made from free microwave oven transformers and rate wire) and capacitors for smoothing more the voltage too. Awesome made in the US rescue and restore. I found a $20 Miller Thunderbolt that's a newer design though broken fan, no case cover, no dial handle and I hope that's all. I haven't started working on repairing and restoring yet since will be a custom upgrade to DC project... though I think I have all the parts and am even using a free microwave case to make the new cover. Thanks for sharing.

[@thewanderingrays5131]

Hey that actually seems awesome keep me posted on that project!

[@jafinch78]

@@thewanderingrays5131 Will do. Reminds me, I don't recall making any videos regarding and haven't even took many photos of. Maybe can make a photo montage with text or narration detailing all the parts I've sourced and get that up sooner than later. Just checked the Hackaday article regarding I submitted as a tip that I have comments on and a reference to my facebook that has the photos I was recalling. hackaday.com/2019/09/12/modified-tombstone-welder-contains-a-host-of-hacks/ Wound up getting hooked on a couple of buzz box designs I found on either FB Marketplace or Craigslist..., not thinking Offerup/Letgo, when searching around, from the one I mentioned to the $50 up to $125 or so other three.

[@StonemanRocks]

Thats what im doing to mine is dc convert! I got diodes online and built rectifier from a micro trans as well! Are the capacitors really neccessary overall i mean would it work without them? I was having trouble finding them and was thinking i might try it without the caps !

[@jafinch78]

@@StonemanRocks Man, I still haven't moved forward on this other than more part. However, I was just reviewing mods for the Century 125GL, since picked up a 100 and they noted the same for their DC system that did help smooth the arc and reduce spattering and like the half wave rectified pulsing like signal effect. They're not cheap and I just looked on eBay like for the 125GL rated 30V (thinking double is better since ~25 short circuit voltage) 64000mfd (check your specs which is used). That 125GL is half bridge rectified so like a 60Hz wave if not smoothed with a big cap and/or inductor. If you have a full bridge rectified design you'll get double the waveform since the bottom negative AC is inverted to DCEP at 120Hz until smoothed by a cap or inductor... might not help as much... though can. Just make certain you add a bleed resistor across the cap. Read into that without a doubt since without can kill you. I read some if not many use parrallel resistors for backup and higher wattage rating so last longer. The way without caps and is safer is find old microwave oven transformer (MOT's) and cut out the wire and rewind into a inductor (choke they're called too) and that will help smooth out the waveform current which I believe also effects to smooths out the voltage. I made a video on my YT channel maybe a week or so ago with links in the description to the broken links on that hackaday article that might help.

[@StonemanRocks]

@@jafinch78 hey thx brother for the info! I have already made the rectifier from a microwave transformer and i bought some diodes online. They are rated for 200a so they are big enough I think! I know that bleed circuit is important as well thx for reminding me! This is one of those projects i started and it got shelved for about 2 yrs. now and i want to finish it! I cheated and bought a smaller lincoln wirefeed and been relying on it to get stuff done but my miller thunderbolt welds so much hotter and is needed for bigger stuff plus its way faster! Ill prob order some caps and do it right along with the bleed circuit! I had forgotten about that bleed circuit actually which might not have been good! Thx for getting back to me as soon as you did! You may very well have saved me from myself!

[@StonemanRocks]

I love my thunderbolt! Dude those welders were built to last and to work all day everyday you should use the crap out of it!

[@thewanderingrays5131]

yes absolutely i love mine i need to do more welding with it

[@danbeckstead2020]

Looking forward to part 2

[@thewanderingrays5131]

Comin soon! Ive got some irons in the fire now but it won't be long!

[@will-dd7ou]

has the grease caused any problems? i have a 75 model and am thinking of doing the same.

[@thewanderingrays5131]

not at all been great

[@romi.1741]

Amigo me podrias indicar el calibre de alambre en el bobinado primario

[@jonathanortez5520]

How did you get your cover off, I can't figure out how to take crank off

[@thewanderingrays5131]

There’s 3 aluminum flathead screws on the top of the crank handle that you have to be extremely careful with because they will strip out! Fortunately mine came out good but I was sweating lol

[@jonathanortez5520]

@@thewanderingrays5131 I guess someone stripped them out before and riveted it back in, drilled through rivets and it came off

[@thewanderingrays5131]

@@jonathanortez5520 I’m glad you got it figured out, I hate they did that too it

[@fernandoalanis3324]

I'm unable to remove the cover. I was able to remove the 3 screws and the crank but it still has the piece of metal where the 3 screws go screwed on so the cover can not slide out of it.

[@thewanderingrays5131]

@@fernandoalanis3324 should just remove the screws which you did and pull up on the piece it should come off

[@nicolejenks1504]

What happens if those copper rods brak behind the ground and rod connections

[@thewanderingrays5131]

Lol I wouldn't even want to find out but it would probably electrify the blue casing and electrify you badly

[@StonemanRocks]

Why would they break?

[@j.asuncionornelas7306]

Good

[@rafaeldominguez2472]

I got a miller 225 and suddenly it make a big explotion on the bottom and i can control the heat after that maybe do you aveand idea what was wrong any help please

[@thewanderingrays5131]

Not sure what would have caused it buddy, maybe check the adjustment track or the threads on the adjustment rod

[@kayman331]

How bout that part 2

[@thewanderingrays5131]

I do need to get that part 2 goin huh

[@russ9983]

Can anyone explain to me why blocking out 70 percent of the screen is good?

[@thewanderingrays5131]

I can’t explain that but I can tell you that it’s just the way the video posted,,,

[@paulamenco5343]

En español por favor

[@thewanderingrays5131]

i no Espanola i sorry