Introduction: Small 110 Volt Arc Welder (NYDG)
Im going to write a ton of Instructables on how to make Not your Dads Garage but work area designed for the future of builders. I will work in an evolution process to more and more complicated project, using project in past Instructables to help current project, assuming you have access to your dads tools (Hammer, Screwdriver, Saw, Drill,)
We will start by making a 110 Volt Arc Welder, 220 would be nice but most Instructable starters dont have a 220 outlet. It needs a little solder so you will need a soldering iron.
Step 1: Building the 110 Volt Arc Welder Housing
Make sure its strong, it will way more that 100lbs
1. 2 x (30 inch x 24 inch x 1 inch) SIDE
2. 1 x (25 inch x 36 inch x 1 inch ) FLOOR
3. 2 x (24 inch x 36 inch x 1/2 inch) Levels
4. 4 x (36 inch x 4 inch x 1/2 inch) Walls
5. 1 x (37+ inch x 2 inch Dowel) HANDLE
Step 2: Electronical Parts
I have had the best luck getting microwaves from Secondhand stores, for free or less than 5$ each. But you could check the junk yard, and other places, just dont break yours for the parts (popcorn is better than a welder).
1. 10 x Microwaves @ 900+ Watts
2. C1: 600pf 2kv ceramic
3. C2: 0.1mf 400v epoxy
4. R1: 1M Linear potentiometer
5 .R2: 5k Linear potentiometer
6. C3: 22mf 250v electrolytic
7. Q1: IRKT71 SCR module
8. Q2: Lamp dimmer triac
9. BR1: RB152 1A bridge rectifier
10. D1: Trigger diac
1. Wire Cutters
2. Wire Strippers
3. Soldering iron
5. Basic screwdriver set
6. Elbow Grease
Step 3: Moding the Transformer
Microwave oven transformers are step up transformers. That means that the voltage at the secondary winding is higher than the primary 120 volts. The secondary voltage is typically 4000 volts. Replace low voltage winding with #6 Single conductor wire, about 10-18 wraps. The load will change to 10 volt, and during welding will be about 2-4 volts at 250 amps.
Step 4: Electronical Parts
Assembling the Electronic Part onto the Caring Case.
Just follow the Schematics and make sure you get all the (step transformers) in the correct placement.
Easy to follow Schematic... Thanks too.... http://www.dansworkshop.com/index.shtml, with minor changes.
Step 5: Finished Product
Special thanks to my electronics college teacher for giving me the idea and the special thanks to the web for donated material, pictures and information. Remember safety.