Introduction: How to Build a Simple ARC Welder.
6 Gauge wire or other thick insulated wire
A hack saw, grinder or chisel
Pliers or wire strippers
Estimated build time: 35 min
A short video: http://youtu.be/wwAyC4E-4wQ
Step 1: Find a Transformer
You will need a large transformer, about 4" by 2" by 4". These are found in microwaves, electric mowers Etc.
Step 2: Remove the Base
Use a hacksaw, grinder, or chisel to break one of the welds holding the base to the body. Remove the base.
Step 3: Remove the Coils
Remove the main and secondary coil. You will need to larger wired one, so be careful. The smaller wired and mid coils are unnecessary.
Step 4: Reinstall Main Coil
You will now reinstall the main coil onto the transformer. Simply slip it back on, and push it to the bottom. Sometimes the use of a rubber mallet is required. This is ok, just be sure to not injure to coil.
Step 5: Install a 6 Gauge Wire
Find a 6 gauge wire, or any (insulated) wire or bundle that will fit snugly around the center "pillar" of the transformer. You will wind this once.
Step 6: Re-Assemble
Use epoxy, a welder, Jb welds or even duct tape to reattach the base.
Step 7: Add a Switch
Find a 120v power cord that is Un-needed. Cut it to a desired length, and make sure to not cut the plug off. This will be needed to plug into the wall.
Splice the wires, and find 2 connectors that will fit on the coil leads. Once your wire is spliced, take one of the leads and chop it to about a foot. DO NOT CUT THE GREEN ONE. IT IS THE GROUND. It does not matter which of the others is cut.
Attach the shorter wire to a terminal on a 120v switch. Take the piece you chopped of and add it to the other terminal of the switch.
Attach the clips that fit on the transformer to the wires.
Step 8: Mount It
Mount the switch in an electrical box, and the transformer on a piece of wood.
Step 9: Attach Conducters
Attach a conductor to each end of the coil of 6 gauge wire that is running through the transformer. I used 2 welding rods.
Step 10: Try It!
Put in some rubber gloves, check for bad connections and turn it on! It will buzz, and when the leads coming off the 6 gauge wire touch, they will spark fantastically and easlyelt coins and nails.
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I take no responsibility for any injuries caused by this post or in direct relation to it. Have fun!!