Cheap Welding for Punks

Step 3 AC Stick

Weld Steel, stainless steel and (sort of) aluminum.
Cost: $0 and up.
see the entire DIY AC Stick Welder Instructable.

It costs nothing to make. The junk you need is probably already in your alley or garage. A bundle of rods costs $7 or so anywhere in the world.
It's much easier to make this welder run on 220 volts than on 110, since it draws half as much current on 220 and your breakers are less likely to blow.
Striking an arc without sticking the rod to the work is a skill, look for some instructional videos on youtube. I do it by listening. It makes a particular sound when you do it right.
It's very easy to weld on steel that's about the same thickness as your welding rods or a little thicker.
For thinner walled stuff it takes some skill and looking up the proper settings.
Stainless is also easy to weld with this unit. Just get some stainless rods at the welding store. Use low power and thin rods, stainless is a poor conductor of heat and it's easy to melt through. But it's easy to make it look nice. It's "stainless" so it's easy to make nice shiny welds.
They sell aluminum rods also, but I've never gotten them to work for me.

Comments

[Krimm]

I got a System that can weld two pieces of wood together. I'll post instructable later

[chip123]

Is it called glue, by any chance? :P

[steamer551]

alumaweld is the easiest way to weld aluminus together. You just need a propane or map torch. ey also have rods for welding bronze and brass.

[abose89]

Sir, between this project and your home made gas mask, you are f$*king insane, and if I ever meet you I'd love to shake your hand :-)

[wackyvorlon]

Bear in mind: Welding with AC is much harder than welding with DC.

[darthdork]

i find it easyer

[2 stroke]

me too i thin ac is easyier because no arc blow whick is fu_ _in annoying

[Coffee bean]

y is that?

[wackyvorlon]

The polarity is changing sixty times per second, so the arc is constantly stop and reestablishing itself. Makes the whole thing vibrate and the arc is very hard to keep going.

[Metalcaster14]

yeah but remember that with DC you get arc blow which is pretty freakin' annoying

[fieldman]

If you want to weld DC, look around for an SCR bank from a variable speed DC motor drive. I pulled one out of a dumpster and put the leads from an ancient Marquette (massive coils) through it. Best welder I've ever used and that includes a lincoln upright with foot pedal. The problem with small coil welders is the inrush current when an arc is struck. Put a capicator bank on them and they should work a lot better.

[Astinsan]

Depends on your local manciple power. You may be on a 50hz system like in the euro countries. You are correct though. After a person masters it, there isn't a problem getting and keeping it going. If you are to do a weld on something that really matters, one would use a dc welder or tig welder.

[BeanahVulgaris]

There is a patent of Nikola Tesla's that talks about rectification. This would allow higher currents with less loss from the semiconductors. US pat 413353, some of the illustrations are to show the idea rather than an industrial use.

[stasterisk]

that's a massive overstatement! both kinds of welding are easy.

[wackyvorlon]

Not if you need a code weld.

[iBurn]

...In all fairness...if you're doing a code weld, you PROBABLY aren't using these methods...

[Coffee bean]

and that is

[wackyvorlon]

In Canada, it is regulated by the CWB. It's a standard for weld quality and strength. Pressure vessel welds are regulated by the TSSA. Until my tickets lapsed, I was ticketed in two positions for the CWB, and all-position for pressure welds.

[Scubabubba]

If you have to make a weld that is legally "safe", like on a bridge or a pressure tank, you have to follow a code like the building code.

[Coffee bean]

i agree with iBurn because anybody welding a bridge or a tank or things of that sort will have exp and probly store bought welders

[masterochicken]

And much more importantly, certs.

[killerke]

Welding with is oldschool, that wath i think.
I've been schooled for 7 years in welding that is tested with RX pictures.
Most of it was welded with TIG(wig) and MIG/MAG

grtz

[Pablo_Sanchez1987]

In case any were unaware, you can use that same aluminum stick welding rod to oxy-fuel weld. Try it, practice makes perfect.

[okieman]

OK if you want to weld aluminum (with aluminum rod of course) remember that aluminum diffuses heat very quickly, so first take a torch and preheat the joint you want to weld on for a few minutes.(I suggest putting the work on a fire brick or some type of insulator so your table doesn't soak up all your heat)now you may have to play with it to get the right amount of heat. but the overall result is that the metal flows together much better.

[twhaley]

I welded my tonge to a flagpole once, on a dare.

[static]

Do you know getting someone to pee on your tongue, would "unweld" it?

[Kryptonite]

Uhhhhh, how precisely?

[Wolframite]

 The pee from their body would easily be warm enough to melt the frost sticking your tongue onto the flagpole and the bond would be broken.

[Kryptonite]

I was asking twhaley but oh well.

[Wolframite]

 Oh, oops.

[Scythan]

Aluminum, if difficult to weld. You need to have your rod angle pretty much dead on (varies depending on what position you are welding) and same with the settings. Another thing to keep in mind is that the fumes from Aluminum are also alot more Hazardous than Mild or Stainless Steel. It produces alot of smoke, so it would cloud up your lenses fast if you don't keep clear.