Introduction: Machining Replacement Tips for Harbor Freight Spot Welder

Picture of Machining Replacement Tips for Harbor Freight Spot Welder

The contact points of our Harbor Freight spot welder had gotten too pitted and damaged to work.  I had no luck getting replacement parts from anywhere, so I made a replacement set.  I used TechShop San Jose's lathe to make the parts. 

Step 1: Load Copper Rod Into Lathe With Collet Closer

Picture of Load Copper Rod Into Lathe With Collet Closer

I bought a nice copper rod from McMaster-Carr - it wasn't cheap, but it was less costly than a new spot welder.  The piece was 3/4" in diameter, so I used a 3/4" collet to hold the rod. 

Step 2: Cut Thread Side to 8mm

Picture of Cut Thread Side to 8mm

The threaded part of the tongs that the tips screw into are 8mm, so the plan is to cut the copper shaft to 8mm. 

Step 3: Cut Angled Tip

Picture of Cut Angled Tip

Using a triangular cutter, I shaped the front of the part to resemble the bad one I had taken off. 

There is no need to part the piece, as it will pop off when you get mostly done shaping.

Step 4: Thread the Back Side

Picture of Thread the Back Side

I used a die to thread the back side.  Shiny!

Step 5: All Done!

Picture of All Done!

Install the tips and weld!  The originals had flats to use a wrench to install them, but a pair of pliers or vice grips works fine.


WillH8 (author)2015-06-25

I found replacement parts by calling Harbor Freight. Here's the info

The part you are requesting can be ordered by contacting our Inbound Sales department at 1-800-423-2567. They are available 24 hours a day 7 days a week.

SKU# Part# Description Price (plus tax & shipping)

15551 24 61205/61206 ELECTRODE TIP 2PK $15.99

scarr2 (author)2015-01-18

This is a great project and you obviously put a lot of thought and craftsmanship into it. FYI does sell new tips for the HF spot welder. Good job though!!!

mackamitsu (author)2013-09-26

you can file a pair of flats on the tip to use a wrench if you want.

klee27x (author)2013-09-16

I'm curious. Do you buy taps individually, where and when you need them for specific tasks? Or did you buy a complete set of them up front? Or do you find there are a few key sizes that are your go-to's that cover most of your needs? If yes to the latter, which are your most frequently used taps?

BradMartinson (author)klee27x2013-09-16

I have usually invested in full sets of taps over the years - a nice combo metric & SAE set has kept me company for about a decade now. Craftsman brand, as I recall.

However, for this project, I was able to use the ones at TechShop San Jose to do the job -- they have a complete set available for member use.

audreyobscura (author)2013-09-15

Great job!

audreyobscura (author)2013-09-15

Great job!

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