Wow!!!!! Make an Amazing Spot Welding Machine DIY

Introduction: Wow!!!!! Make an Amazing Spot Welding Machine DIY

About: Its all about life hacks, tools, scientific & creativity instructables ~ electron7m

Hey Guys!!!!

In this instructable you will learn how to make a very powerful spot welding machine at home using capacitor bank.This set-up is mind blowing for doing welding in remote areas or even on the way.

Even though many of us already have Electrode welders but they consume too much electricity and the gas fumes are very harmful for lungs.

In this system a 12 volts UPS battery or a laptop charger of 15V O/P will power up the machine.

Full Video :

Credits : Mr Electron

Step 1: Connecting the Capacitors :-

Get 7 electrolytic capacitors rated at 200 to 250 volts and 10000 microfarad each, glue them to a wooden board and connect all of them in parallel.

You can also connect the car jump start cables to the tapping point of these capacitors.Stick the capacitors together in one place to some wooden base like I did as you can see in the picture.

Full Video :

Credits : Mr Electron

Step 2: Full Circuit Connections :-

Take a bridge rectifier and connect the DC output of the rectifier to the respective positive and negative of the capacitor Bank.Attach the rectifier to the wooden board as well.

Now take a bulb holder and place it on the wooden board.You will also need a two pin plug that is to be attached to the inverter box as you can see in the picture.

So 1 wire from the two pin plug will be connected to one of the AC input terminal of the rectifier and the other wire will be connected to one of the wires of the bulb holder.The other wire of the bulb holder will be connected to the other AC i/p terminal of the rectifier.

Now what you are going to need is a 100 Watt 12 volts to 220 volts inverter. Connect the two pin plug to the output circuit of the inverter and connect a 100 watt bulb to the bulb holder.
Take a multi-meter and connect the positive terminal of the meter to the positive terminal of the capacitor Bank and the negative to the negative terminal of the capacitor Bank.Move the pointer to 1000 volts DC and place it somewhere where you can see it. Now all you should be left with is just 4 terminals 2 of which are the jumper cables connected to the capacitors while the other two are the input terminals of the inverter.

Full Video :

Credits : Mr Electron

Step 3: Placing of Metals to Be Welded Together :-

Now the jumper car cables come with pre-attached crocodile clips.

Connect one clip to the drill chuck part of a drill press for high precision and the other one to the vise as shown in the pics. Make sure that the 2 bodies are separate.

Take 2 metal pieces to be welded. Connect one to the vise and the other to the Drill Chuck or to a wooden stick for handling if you don't have a drill press.

Now take your 12 volt 7 Ah UPS battery and connect the positive input terminal of the inverter to the positive red terminal of the battery and the negative input terminal which will be the black one to the black terminal of the battery. Your 100 watt bulb should be glowing brightly.

The multi-meter display will keep on indicating the voltage value to which the capacitors have been charged that is a bulb luminescence will keep on decreasing with the increase in voltage displayed on your multi-meter display until it becomes zero.Keep charging the capacitors at least up to 200 volts.

Full Video :

Credits : Mr Electron

Step 4: Testing :-

After the multi-meter indicates 200V or 200+ volts, wear your eye protection glasses & rubber gloves.

Touch the 2 metals together with the drill press lever.There should be a loud sound and too many sparks as soon as the 2 metals get in contact.

You should be able to do welding with it easily.

Perform the same test with other metals too and it should perform great.

So guys, that's all for today's instructable.


Full Video :

Credits : Mr Electron

Be the First to Share


    • Metalworking Contest

      Metalworking Contest
    • Maps Challenge

      Maps Challenge
    • Tinkercad Student Design Contest

      Tinkercad Student Design Contest

    3 Discussions


    9 months ago

    Why not using a transformer instead of capacitors? It is safer to use a transformer to step up the amperage for a spot welder. Capacitors can hold a lethal charge and your arrangement has some exposed wires and you also lack a non conductive enclosure. That is a recipe for a disaster. An electric shock as little as 30 volts under some conditions could be fatal and you are dealing with 200 volts.


    2 years ago

    (1/2)CV**2 at 200 volts and exposed wiring. Some major warnings are in order.


    Reply 2 years ago