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Step 7Safety Measures
I have received some negative press regarding safety (and rightly so). I decided that I should add a box around the transformer. It will provide protection for the operator and avoid any exposed 110V contact completely. Going with the idea that it can built without purchasing anything I started scrounging around for a box. They were throwing out a broken PC power supply at work.
SAFETY NOTICE: PC power supplies contain large capacitors that can store energy for a considerable amount of time (days). I checked with the person that removed the power supply and he told me that it had not been plugged in for quite some time (months). The shock isn't likely to kill you but it will make you wish that you had waited a little longer to open the box. Please use common sense.
I removed the internal parts from the box and put them in the pile of e-junk that is scheduled to go off to the recycle depot. I left the switch and plug to avoid open holes but you can cover it with gaffer tape or electrical tape instead. Don't use the switch in these boxes as they are not rated for 15A. I also left the ground wire that is attached to the box. I carried a third wire to the box and grounded it. This effectively grounds the core of the transformer which is now attached to the bottom of the box.
The box can be modified with tin snips if you take your time. I use pliers to bend back any parts that are twisted after cutting. Electrical tape to cover any sharp edges or protect insulated wires. I tested everything after I was done. It increases the audible hum that the transformer makes when it is on. I had considered adding a light that would indicate it was on, but I don't think that's necessary. I know exactly when it is on.
I also talked to a friend of mine who works with a spot welder at an HVAC factory in town. He said that the boxes they were welding would occasionally short across the tubes instead of the tips. It doesn't harm anything but it prevents the welding. They solved the problem by wrapping the tubes in electrical tape.
I hope that this gives you a fairly good idea of how to make this device even safer to operate than it was originally. Please use caution as this device is not a toy. Serious burns and/or electrical shocks are possible if safety is not your primary concern.
SAFETY NOTICE: PC power supplies contain large capacitors that can store energy for a considerable amount of time (days). I checked with the person that removed the power supply and he told me that it had not been plugged in for quite some time (months). The shock isn't likely to kill you but it will make you wish that you had waited a little longer to open the box. Please use common sense.
I removed the internal parts from the box and put them in the pile of e-junk that is scheduled to go off to the recycle depot. I left the switch and plug to avoid open holes but you can cover it with gaffer tape or electrical tape instead. Don't use the switch in these boxes as they are not rated for 15A. I also left the ground wire that is attached to the box. I carried a third wire to the box and grounded it. This effectively grounds the core of the transformer which is now attached to the bottom of the box.
The box can be modified with tin snips if you take your time. I use pliers to bend back any parts that are twisted after cutting. Electrical tape to cover any sharp edges or protect insulated wires. I tested everything after I was done. It increases the audible hum that the transformer makes when it is on. I had considered adding a light that would indicate it was on, but I don't think that's necessary. I know exactly when it is on.
I also talked to a friend of mine who works with a spot welder at an HVAC factory in town. He said that the boxes they were welding would occasionally short across the tubes instead of the tips. It doesn't harm anything but it prevents the welding. They solved the problem by wrapping the tubes in electrical tape.
I hope that this gives you a fairly good idea of how to make this device even safer to operate than it was originally. Please use caution as this device is not a toy. Serious burns and/or electrical shocks are possible if safety is not your primary concern.
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You should mention something about getting a bit of soldering flux, and brushing that onto the work before spot welding. It can make the difference between a great weld and a poor one.
Great instructable!