Super Scary Weldy Thingy Part 2 (DIY Spot Welder)

In Part 2 I will show the assembly of the transformer and the front end mechanical components of a DIY spot welder. I also show the powder coating process for finishing the castings and other metal components of the welder.

[@ScottDube1]

Amazing work on this. I really want to learn casting after watching you and a few others. So many tools so little time!

[@Preso58]

Scott, being able to make your own castings opens up a whole new range of possibilities. When I made that spot welder I had only been making my own castings for a few months. I hate to think how I would have made that machine if I had to rely on fabricating everything. With a 3D printer and some basic tools you can make things that would otherwise be very difficult or impossible to make any other way. I was surprised at my early successes but of course, I have had plenty of failures too. Regards, Mark

[@reiniertl]

That is freaking piece of machinery. This is the ultimate home shop made spot welder.

[@Preso58]

I must say that when I started that build I must have been quite naive. I had no idea if it was actually going to work but went ahead anyway. As it turned out I was pleasantly surprised when it did exactly what it was supposed to do. Regards, Mark

[@rupert5390]

really nice work - I love the understated aussie way you just made a professional spot welder, with your home made 3d printer cnc mill and adapted powder coating oven - congratulations - really great channel.

[@smoovecee]

This is a most impressive project! I have wanted to build a spot welder from a microwave transformer, and you have provided some real inspiration. Can't wait to watch the next part.

[@Preso58]

Thanks for that. I must say that I built my spot welder without a specific project in mind for it. I guess it just became a bit of a challenge and I do get a bit obsessive about a project once I get started.

[@bobvines00]

Mark, I'm watching your videos out of order, but now that I see your DIY spot welder, I may have to build one too. However, the last time I described the modification of a microwave transformer modification to the Senior Electrical Engineer at work, he almost jumped out of his chair telling me how unsafe it is. But since so many people have successfully done these mods, I may go ahead and try it. And not tell the E.E. that I did it anyway.

[@Preso58]

Well, I am normally very wary of anything to do with mains voltage but everything past the primary winding appears to be fairly safe. The secondary winding only delivers around 1.5V and this seems to be non lethal. I guess you just have to take sensible precautions. Go for it I say!

[@mrimmortal1579]

Greetings, Mark Presling! I know this is an old video, but I’m only just now catching on. I was wondering if you had ever tried putting the foam spacers (the ones that prevent your secondary windings from dancing around) ABOVE the secondary windings, instead of below. If so, did you notice any sort of difference in the overall power of the welder?

[@Preso58]

I have since done an upgrade on the transformer using a much heavier cable which fits very tightly into the laminated core. It quietened it down considerably and it now welds consistently and reliably. I never expected it to work as well as it does so I am well pleased with the result.

[@greaser5691]

2:34 Your neighbours obviously weren't happy about the powder coat colour (Graham Kennedy-style!) :)

[@MatthewTinker-au-pont-blanc]

Did you think about two microwave transformers in parallel? Although they could be used on single phase, it would be possible if you have three phase to wire the on two phases! Nice build. Regards, Matthew

[@Preso58]

I believe some others have done this. As it has turned out my latest iteration of the welder does everything that I want with just the one transformer. It took a few goes at designing the secondary winding but so far it seems to suit my needs.

[@JeffKirschensteiner]

Nicely done and very impressive. What do you do in your spare time :)

[@Preso58]

Yeah! Don't have much of that. Now that I'm retired I can't work out how I had time to have a job.

[@joell439]

👍👍😎👍👍....... simply - WOW

[@marianodiaz461]

mark Sorry im missing something, how do you insulate the arms with the rest of the machine?

[@Preso58]

Mariano, there are two delrin bushes with flanges larger than the bolt heads in the bottom plate to which the fixed arm casting is bolted to. The bolts pull up on these bushes so they are not electrically connected to any part of the chassis. There is also fibre insulation between the casting and the lower plate. So, the bottom copper arm and its mounting casting is totally isolated from the rest of the machine. Only one arm needs to be insulated and it is easier to do the fixed arm. If you are still not sure you can send me your email and I can send you a cutaway view of that section of the welder. Regards, Mark Presling

[@thisnicklldo]

Really nice design - clever mechanism. I'm working my way through your back catalogue, all great stuff. I see you often powder coat and get a very professional look. But, and you're not going to like this, I'm afraid I do think powder coating is an invention of the devil. No form of metal finish lasts forever, knocks and bumps will mar anything, and powder coating is just irreparable. I have a little Unimat 3 that will never look good because it can't be mended, and you can't stop a lathe taking chips. We threw away our last fridge because although it still worked (it's a pump, a thermostat and some shelves, what is there to go wrong?) a Hoover knocked the front panel and the powder coating gradually lifted off. I do see it as a part of the throw-away design movement. When I am Emperor of the Universe (which I think is probably going to happen quite soon) I will ban it, along with sealed beam headlights and sealed central heating 'control units'. But because your videos are so entertaining I will use my mighty powers to grant you a special hobbyist exemption - no need to go into hiding immediately.

[@Preso58]

I have found that the powder coating that I have done in the shop is extremely durable. I had to remove a coating once because it was done on a casting and this produces an artifact called outgassing. Essentially it produces bubbles in the coating and it looks bad. I tried hand sanding, belt sanding, sand blasting and all different sorts of solvents and it proved to be almost impossible to remove. In the end I found out that ordinary paint remover (the super toxic one) works. I think some commercially applied powder coats are quite thin and they do chip easily if the substrate is not chemically cleaned. Baking time and temperature also are important factors in how durable the coating is. Chinese manufactured goods are often painted using epoxy paints that look like powder coat but they don't last because they get painted straight over bare steel with no phosphating or surface preparation apart from a cursory wash with some cheap solvent. I painted my Colchester lathe with two pack epoxy paint and everytime I get a chip in it I cry a bit because it took so long to prep and paint it. Unfortunately it is the price we pay for using the machine in the first place. I am always a bit suspicious of pristine looking lathes. Makes you think they are just show pieces and not meant for serious work!

[@asprot2054]

Bonjour, le deuxième cosse supérieur n'est pas isolé de carcasse ?

[@Preso58]

Non. Le support du bras inférieur est isolé de la carcasse avec des tubes en plastique à l'intérieur des trous.

[@asprot2054]

@@Preso58 vous pouvez m'envoyer les composants électroniques et électriques pour monter cette soudeuse Merci

[@Preso58]

@@asprot2054 Je peux vous envoyer le schéma de circuit si vous m'écrivez à [e-mail] Désolé, je ne parle pas français mais je traduis dans Google Translate ! Salutations, Mark

[@redelala7652]

i have a question? did you cast ir all in alluminum alloy after 3d printing?

[@Preso58]

Yes, all the 3D printed parts were cast in aluminium alloy and machined for the mechanical parts. All the 3D models for the patterns are here on thingiverse www.thingiverse.com/thing:2368142 Regards, Mark

[@redelala7652]

@@Preso58 thanks Mark Presling im interested making gone for project use at home

[@kennethmoller1]

What powder kit do you use ?

[@Preso58]

I bought the Eastwood single voltage powder coat kit. Mine came from the USA and it came with a selection of powders and some silicone plugs and stainless steel tie wire. I did a video on the process here kzbin.info/www/bejne/hWOtmIWlfZugmrM Regards, Mark

[@kennethmoller1]

@@Preso58 Thank you Mark ,