Super Simple DIY Spot Welder Pen (MOT Battery Tab Welder Pen) 10$

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Introduction: Super Simple DIY Spot Welder Pen (MOT Battery Tab Welder Pen) 10$

About: I mainly take on projects I have seen here and put my own twist on them. I also like to take garbage or thrown out electronics and make something nice from them. I have no certain area of Expertise, I am new...

I was looking at all the sites online that sold Spot welder pens and saw how a lot of them were put together. I came across a set that was cheaper than the rest, but still a little more than I could afford. Then I noticed something. Everything they used to make those pens, I already had on hand. Even if I was to repurchase everything the cost would be smaller than purchasing from the site I was on. So for under 10$ I made myself a great pair I use daily to this day. Here are the simple parts needed for this build. My cost was supper low as I already had the parts from previous projects.

Supplies:

3/8 Copper Lugs($1.63) x 2-

https://www.digikey.com/product-detail/en/molex/01...

7× 0.5-3mm Small Electric Drill Bit Collet Mini Drill Tool Chuck Tools Kit($2.69) x 2-

https://www.ebay.com/itm/7-0-5-3mm-Small-Electric-...

K&S 7/16 in. Dia. x 12 in. L Round Brass Tube 1 pk ($3.59)

https://www.acehardware.com/departments/hardware/m...

12" Piece of 2 gauge Silicon Wire($1.50)-

Was a spare scrap I had laying around, can be any gauge doubled up or bigger with some of the wire pulled out.

Shrink Tube I had from previous stock($.20 cents)-

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Step 1: Drill Small Holes to Align the Bit, and Spot for Soldering Later

Using a 1/16-1/8" drill bit, I drilled holes to match the drill chucks Allen screw holes. I also drilled holes in the middle of the pipe, I cut at 6" and drilled a hole in the lug. These are places I will use to screw the drill chuck to the pipe and the others just make it easier to add solder later on.

Cutting the Pipe at 6" gave me 2 pieces the perfect size. You can cut your pipe to fit your needs. Some DIYers like smaller Pipe, or shorter. Just make sure to use the perfect size to fit the drill chuck.

Step 2: Take the 2 Gauge Wire and Cut the End for the Copper Lug Then Solder

Cut a smaller piece of the insulation, from the 2 gauge copper wire and then slide into the lug. Using a small torch, or strong soldering iron. Heat up the lug and add enough solder to make sure it is solidly connected to the wire. This is the reason I drilled a small hole in the lug. I have found using my small vise helps keep this in place while I solder and let it cool.

Step 3: Cut the Rest of the Insulation of Wire and Slide Into the Copper Tube, Then Solder

Place the wire next to the copper tube and add lug to get the exact size needed. Cut with Wire cutters and then remove the Insulation. Slide into the copper tube. I used a small screw in one of the holes to hold in place while I solder. Place back in vise and solder in each hole in the pipe. Remove the screw and solder again. Make sure to solder enough to fill the pipe to get a good connection. I again used a torch to help. You can use a torch or a very strong soldering Iron.

Step 4: Use a File to Clean Up and Get Rid of Flare, Screw in Drill Chuck

There was a lot of plastic and flux left over after I soldered. There is also a flare on the lug I did not want. I took a file and got rid of the plastic, flux, and flare. Then I tapered the small hole for the drill chuck. Then added a small screw with a flared end that fit the drill chucks Allen screws holes. You can remove these 2 Allen screws, as you won't need them for the project. I tighten the screw to hold the chuck in place.

Step 5:

Cut and add shrink wrap. I used black, but you could use one black and one red. Before adding the big piece, I added smaller pieces over the small holes where I soldered. Make sure to cover the complete welding tip for protection later. You could here add better grips or even tape. If you used a welder of any type, these get hot no matter what you do when doing larger batteries. with the added copper in the tube and the copper tubing, this should help with the heat. But this is the part, where you do what comfortable for your hands.

Step 6: Add Some Bigger Gauge Wire to the Spot Welding Pen and Enjoy!

This was sooooo simple and I am sure there is room for improvement. I can only hope this inspired you to take what you might have laying around and make something very useful. I make spot welders often and you can find those on my Youtube channel. I have been using these since I made them and they work great! Not bad for 10$ and a little work. What worked out for me, I had all parts laying around in my stock as I had extras from previous projects. Thanks for reading and I hope you enjoy. Please if you like my video, Like it subscribe and share!

Step 7: Thanks for Watching My Video and Reading My Instructable

1 Person Made This Project!

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22 Discussions

1
Aquaticfan
Aquaticfan

14 days ago

Nice build bro!!! Keep it up. I will be looking for your diy spot welder soon!!!
Peace ✌ī¸đŸ™âœŒī¸

1
njfulwider5
njfulwider5

Reply 14 days ago

Check out my Youtube Channel. I have a few on there That I have built.

1
Aquaticfan
Aquaticfan

Reply 13 days ago

👍✌ī¸đŸ‘

3
Aaron5678
Aaron5678

14 days ago

Can you tell us the power source? And how you control the pulse time?

1
njfulwider5
njfulwider5

Best Answer 14 days ago

It depends. I have used this with a Capacitor welder, a Car Battery Welder and a MOT Welder. I am about to release and instructable with a super simple way to control the pulse if you use a peddal. But if you go to my Youtube channel, you will see a few timmers I have built for all kinds of welding.

2
Aaron5678
Aaron5678

Answer 13 days ago

Thanks much for the info. I'll check your YouTube Channel

6
johndmohler
johndmohler

Question 15 days ago

Prolly a dumb question but what are you using as a power source? Just a 12v car battery?

1
njfulwider5
njfulwider5

Answer 14 days ago

I have used this with a Capacitor welder, a Car Battery Welder and a MOT Welder.

2
megolds
megolds

Question 14 days ago on Introduction

Probably a silly question but what do you use for an electrical supply?

0
njfulwider5
njfulwider5

Answer 14 days ago

Are you talking about for the welder? I have used this with a Capacitor welder, a Car Battery Welder, and an MOT Welder. If you mean my bench power supply. I use the DIY version you can find on my Youtube Channel. I love making welders, and Power Supplies!

1
chuck.heaton.10
chuck.heaton.10

14 days ago on Step 7

Are the electrodes suppose to touch the cable inside or is the copper pipe connected to the chuck transferring the electricity. If so could you solider the chuck to the wire and the connector to the end and skip the pipe in the middle leaving the insulation on the wire and heat shrinking the connections? thanks for humoring a newbie to electrical work.

0
njfulwider5
njfulwider5

Reply 14 days ago

The main reason for the wire-copper tube combo is to help dissipate the heat generated and help with solid contact. The wire sits flush against the chuck, but the wire used to weld is pierced in the middle. You could probably get away with leaving the copper tubbinh off, but you'd have to figure out how to keep the chuck in place.

1
MhandF
MhandF

14 days ago

Un test aurait ÊtÊ souhaitable.

0
njfulwider5
njfulwider5

Reply 14 days ago

These are nothing really special and just a basic set of leads for a MOT welder. If you ever build a welder, you would know this would work far better than just wire stuffed inside of the wire. But, If you watch my video's you will see these being used from time to time.

2
throbscottle
throbscottle

14 days ago

It looks as though if you used copper tube rather than brass, this would work without the cables inside. Very clever using the drill chucks. I've been wanting to make a battery tab welder for a long time, I might make a pair like yours to connect to my MOT spot welder.

0
njfulwider5
njfulwider5

Reply 14 days ago

Thanks!!!!On the build in the video, I used Copper Tubing from the local McLendon's. But on a set I built for my friend I used the same copper/Brass tubing in the link. Both worked equally the same. The Brass tubbing uses 85% copper. But the copper tub is really only there to create a handle and to hold the chuck in place, as the wire in the middle is also touching both the chuck and the lug. The combination was to help dissipate the heat generated when making multiple welds. If you don't plan to use wire in the middle, I would probably advise you to use solid copper. Just watch the heat generated by the welds.

1
jds1969
jds1969

16 days ago

Nice Instructable. I've been considering how to do something like this.

0
njfulwider5
njfulwider5

Reply 16 days ago

Yes, very easy to build with tons of room for improvments. Cheaps parts most of us already having laying around if you do allot of diying!

0
jds1969
jds1969

Reply 16 days ago

I'm wondering, what did you use as the sharpened tips, copper wire or something harder?

1
njfulwider5
njfulwider5

Reply 16 days ago

I use to just make my own tips from solid copper. But I didn't like how t stuck when I was welding, so I tried Tungsten rods I found out the local hardware store in the welding isle. The Tungsten rods worked well as I just used a simple file to sharpen. I finally started just using the ones you find on Amazon or eBay. You can usually find those for a few $$$