Instructables
Picture of Homemade Stick Welder - From Microwave Parts!
Did you know you can make an AC arc welder using parts from your microwave?  I just finished mine, so join me in this video as we put its welding capabilities to the test!

www.thekingofrandom.com
 
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Step 1: Watch The Video!



WARNING: I run the system on 240 VAC, which is metered by a power controller I built called the "Scariac".  It's similar to the idea of a Variac (variable auto-controller), with a few more hazards to be aware of.  The Micro-Welder itself does not have an on-off switch, and can pose a fire hazard if plugged directly into a mains power socket.  I made this to be used exclusively with the Scariac.  (Look for how to build that in another project.)  Stick welding, and/or the modification of a Microwave Oven Transformer (M.O.T), can be very dangerous and presents risk of UV radiation, shock hazards, burns, fires, fumes and a multitude of other risks.  This project should not be attempted without adult supervision and adequate training.  Misuse, or careless use, of tools or projects may result in serious injury.  Use of this video content is at your own risk.
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jwciesle2 months ago

I've been looking to build a MOT stick welder for some time now and I have to say, yours does look great and most likely the one I'm going to model after.

I'm a bit confused when it comes to the Scariac though. You had mentioned that at short circuit the voltage was 36V but what value was the current at this voltage? Im wondering because I would like to replace the Scariac with a purchasable variable transformer and would need to know what specifications I should be modeling for.

Any recommendations on a variable transformer?

Thanks!

Fixitmyway2 months ago

The King,
Big fan of your projects. I'm in the process of building the stick welder and was wondering how many feet of wire it took to do the new secondaries on the transformers? I'm getting ready to buy the wire and don't want to get too much or too little.
Thanks!!!

Do you know anyone that sells these or would sell one?
moorjust1 year ago
as soon as I get a little time in my life haha I will then post the new video. I have been planning for some time to show the results. as for the dimmers.... it's very important that you use them on 120 volt socket and before the Transformers. if you use them on the duty cycle side of the circuit they will very quickly pretty much explode. I have not tried this myself but I know that the results would be disastrous and very dangerous. so in other words you use the dimmers between the wall and the welder not between the welder and work piece. there is no kind of voltage that it can't handle in that space. plus it is way safer than operating welder near a tub of water haha. let me know if you have any more questions. and I know this is not very grammatically correct but I'm speaking into my phone and I don't have my hands free to edit so I apologize for that.
The King of Random (author)  moorjust1 year ago
I'm looking forward to seeing your work, and yes I did try the dimmers on the primary side as you suggest and they failed every time. The MOT's are around 1500 watts and the dimmers are only rated for 600 watts.
hello I'm french and my home, the area is 240 volts but not wanting to work on 440 volts to power my house soldering station is thanks to your method I put my two transformers in parrallel and it works perfectly I wonder why you feed your system with 220 volts then you could supply it with 110 volts? I watch all your videos on like that!
I have plenty of welding experience thanks to TSTC in Waco, Tx. The really did teach me a lot about welding, but i gotta say...

I want one of these. Having one of these could prove useful in a situation such as an economic collapse.
HammE1 year ago
Would the welds be strong enough to build a homemade bike?
cliffyd HammE1 year ago
what type of material are you using, Mild steel? I would think if you kow how to weld it would be, looks like it burs rod well!
HammE cliffyd1 year ago
Yeah, mild steel would be it. Thanks! I'm thinking of using a microwave transformer, wounded 40 times (like i've seen in a video), and use a light dimmer to control amperage.
cliffyd1 year ago
I am a certified welder i all position SMAW, Flat GMAW & FCAW. I've been weldig for 19 yrs. and you seem to being doing pretty good. I would like to ask if you get a hold of any 7018 rod try to see if it's capable of vertical, horizontal & overhead. I do't see why not looks like a pretty cool little rig.
So I built one a few years ago, but could not get it to work. from your instructable I found out this method of removing the 'I section'(?) and winding the secondary on a jig. Which made the project possible again :). I tried to wind it without grinding the transformer open and that was a pain. It was quite impossible to get enough of winds...

But a question. There is no need for an electrical connection when you glue the transformer back?

Good instructable!
stresser1 year ago
My guess about moorjust's dimmers; he's probably got some heavy duty ones, for industrial/commercial or he's got some in parallel and is setting them all the same to spread the load (or has some linkages to do the same.)



4 in series parallel might work with 240v but I'm not an electrician, nor have a stayed at a holiday inn last night.
devangs31 year ago
6.5kWs from a microwave! pretty cool :)
onrust1 year ago
This just ROCKS!
geocrasher1 year ago
I built a welder a few years ago using two MOT's. The primaries were wired in parallel to 120v AC and the secondaries were in series. They were re-wound with 10ga stranded copper wire. The on/off switch was a light switch! There was no heat control, so you really had to control that with your technique. It could burn 1/16" rods (601x or even 7014's) just fine. I used a fan from one of the microwaves to keep it cool and did not have problems with it overheating or wires melting. Used old jumper cables for welding cables. It pulled a full 20 amps from the AC and put out a 32 volts at about 70 amps. It worked great for what I needed :) Pics: https://picasaweb.google.com/rykoala/HomeMadeWelder
The King of Random (author)  geocrasher1 year ago
Very cool :) The units I tried with 10AWG all melted the insulation, blew the breakers, or didn't get the weld hot enough to actually make it stick.

I'll check out your pictures. Thanks.
I did in fact have breakers keep tripping, but it was usually to me going past its duty cycle (about 20% I'd say) or if it stuck when striking the arc. I'm SURE that yours is better than mine was. But, they do work :)
The King of Random (author)  geocrasher1 year ago
Thank you very much for the feedback and your experience!
actually for a homemade welder this is the only one ive found instructions for that prove to work, not only MOT but every other kind imaginable, before i came across this the closest one i found was just a little capacitor discharge welder that could barely pass as having a practical use.
people1011 year ago
I LOVE ALL OF YOUR VIDEOS, THEY'VE HELPED ME ALOT
telorand1 year ago
Nice instructable. You might want to consider a welding mask if you plan to continue welding. I noticed in the last photo you just had goggles. UV radiation is a hazard of arc welding and, subsequently, skin cancer. Goggles are meant to protect your eyes during cutting, brazing, and melting, but arc welding produces the full spectrum of UV radiation.
The King of Random (author)  telorand1 year ago
Thanks for your comment, and you're right. I got a nice sunburn on my face after filming that.
Be very careful when welding anything galvanized. The zinc oxidizes and causes some VERY toxic fumes. Ventilation is crucial.
kakumen1 year ago
Very interesting,
Please add more infromation about security. Use a helmet not googles, protect your self against the sparkles and the high UV.
Misac-kun1 year ago
That "Scariat"...
The King of Random (author)  Misac-kun1 year ago
Scariac. Short for Scary AC
Take a look here: http://www.instructables.com/id/Water-and-salt-Welder/
A bit familiar...
The King of Random (author)  Misac-kun1 year ago
I see what you're talking about now. The idea of an electrolytic resistor, yes :) I thought you were saying that you've seen mine.

How did your welder work? I'd be concerned it wouldn't deliver enough amps to weld anything. 15-20 amps at the most before your breaker blows?
Yeah, something like that :(
The King of Random (author)  Misac-kun1 year ago
It's a creative idea and out of the box thinking :)
Thanks :)
remember to use a GFI breaker :)
Great project, reminds us all that we don't have to go out to some machinery store to buy something when you've got an Instructable that shows you how to do it yourself.
How are you handling the hydroxy gas made in the Scariac. Boom!!
Good question. I haven't found it much of a concern actually. It's AC so the gas production is minimal, and it's fairly well ventilated so it doesn't build up. Have you had any different experience?
While messing with small carbon arc torches several decades ago I used two large fishing sinkers in a open glass baking dish of water and a touch of salt. With the open dish no problem.
t8001 year ago
Another very cool project king, thanks for sharing.
The King of Random (author)  t8001 year ago
I'm glad you like it. Thank you!
czarnian1 year ago
OK, very cool, but the object of the site is not brag about, but tell HOW TO DO IT. Bad karma, dude.
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