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Old 06-04-2010, 06:12 PM
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Default Recent Projects....forge up and running, Stick welder into tig w/pedal

Some pics of my recent projects. First is a 2 burner forge, made out of 2 empty freon kegs. For now I'm only running one burner until I get another paycheck but it gets hot and does its job. Next steps are going to be another layer of kaowool against the back wall and some doors. Burners are 304 stainless, the guy who owns the company I work for managed a machine shop that made them for me. Rest of it are hardware store parts except for some Kaowool from ebay. FYI the thinner Kaowool - I used 1/4" #8, will not hold its shape as a couple websites recommended, I had to drive some roofing screws into the forge to stick thru the kaowool.
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Old 06-04-2010, 06:22 PM
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Next up todays project, I bought an old lincoln AC 225 buzzbox for $50, first order of business was to open it up to clean out the mouse nests then built part of the circuit on www.dansworkshop.com to control phase angle of the power flowing into it.

The pedal I got from ebay had a drastically different value of pot than I needed in it so out came the old and in went a new 1M linear pot from radio shack.

Pics 1,2,3 are of the pedal modification

Pics 4 is of the test circuit assembled on the workbench to power a lightbulb

Pic 5 of the welder without case. One heavy sumbitchin transformer!
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Old 06-04-2010, 06:30 PM
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Pic 1, lots of wasted space in the back of the welder and the fan motor wasn't working so great either. Out came the baffle and

Pic 2 in went some mounts for a pair of brushless fans

Pic 3 Fans mounted

Pic 4 testing driver with everything apart. SCR is an IRKT71/12 SCR module fired by a triac I stole from a fan speed control and an RC circuit involving a .1 uF capacitor and the 1M linear pot in the pedal being fed thru a Diac to the Triac. I'm not completely happy with the performance of the control as it takes about 1/3rd of pedal movement before the SCR fires enough to make more than about 5vac come down the line. A new pot, different value caps and higher wattage resistors are going to be here in a couple days.

Pic 5 detail of driver setup, having shink wrapped all open connections
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Old 06-04-2010, 06:33 PM
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Pic 1 Fans wired in. When I first powered on the noise suppression cap blew up. Two 120V fans wired in series. Fans and massive heatsink were pirated from a Sabina DC motor driver.

Pic 2 wire wrap on the wires running from the switch to the SCR module and back again.
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Old 06-04-2010, 06:38 PM
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so you are making a tig machine out of an old ac welder? interesting, i am going to check out Dan's workshop.
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Old 06-04-2010, 06:43 PM
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Quote:
Originally Posted by akabull View Post
so you are making a tig machine out of an old ac welder? interesting, i am going to check out Dan's workshop.
Dan built a stick welder out of MOT's - Microwave Oven Transformers - that he rewound. Rather than having fixed taps like the lincoln he built an SCR driver circuit to control phase angle of the power going in, I just adapted part of the circuit to fit my needs.

Mike W on the hobart board did more along the lines of what I did and added a pedal to an old Linde stick machine. In retrospect I should have used his circuit instead but the dansworkshop circuit used less components. I do still think the circuit from dansworkshop could work but some values need to be changed.
http://www.hobartwelders.com/weldtal...ead.php?t=4089

My next project once all the parts get here is going to be a high frequency arc starter/stabilizer along the lines of this one: http://www.casano.com/projects/hfstart/index.html

Between these two mods I'll have less than $350 invested and have everything a much nicer tig machine would have except for the AC balance control.
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Old 06-04-2010, 06:46 PM
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I have also herd of using cement in the freon tanks too. never made one so i dont know how it works.
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Old 06-04-2010, 06:59 PM
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Good post! could you make a drawing of the burners?
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Old 06-04-2010, 07:03 PM
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I have used 2 layers of 1" 8# density in all my forges and have not had a problem with it. I buy it from McMaster Carr.
Good job on both the forge and the welder
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Old 06-05-2010, 07:35 AM
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Greenbuggy, The forge is real good. I don't know what kaowool is tho. Does it work like refractory cement? I like that idea.

The tig machine is very cool too. I just need to know more about the wiring. I'm not the electronic guy. LOL It is very interesting how this can be done. This would be a very good way of being able to TIG. Kevin
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