Building A Tig Water Cooler For Dummies!!!

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I have access to a piece of 11 gauge stainless approx 16" x 120". I figure this would make for a great tank for a water cooler.I would like to see this thread take a course where guys like me that know diddly about water coolers could get info like tank measurements, part numbers and vendor info for the other hardware.....bungs, pump, radiator fans.....etc.Thanks in advance!
Reply:I built one a few years ago.Pretty much from junk .It works just fine.Someone had posted pictures and I used them as a reference.For the tank  I used one of those stainless steel Buffet/food trays they use in deli's.My buddy had it in his garage,the motor was salvaged from an old soda dispenser machine and the pump was a Pro Con pump.I got the pump from Ebay,it was like 30.00 and the motor from Craigslist for about 20.00.I had an old heater core from a truck and a small computer fan. The housing is from some scrap aluminum i had and the frame is just some angle iron I had.The rest of stuff(fittings,hose etc...) I got locally from Lowes.I had a pressure gauge and light switch.The most exspensive stuff was the torch and hoses which I  got from Arc zone.I think I have about 100.00 into it,if that .I hope the picture posts.
Reply:There are calculators on the web that can tell you, given tank measurements, the volume of said tank in gallons.Regards,RobGreat Basin WeldingInstagramBlue weldersRed weldersMy luscious Table DIY TIG Torch cooler
Reply:I like the idea. Keep in mind that yhe tank doesn't have to be big. 1 cubic foot holds 8.34 gallons if I remember correctly. The Miller ones I have looked at hold between 1 and 3.5 gallons.Looking forward to lots of good reference material here when I get ready to build one.GravelThe difference between theory and practice is that in theory there is no difference.
Reply:I don't know if I would even build a tank. I figure if I was ever going to go tig and build a cooler I would just use a car radiator as both the cooler and the tank since a radiator can easily hold several quarts of coolant and is already built to dissipate tens of thousands of BTUs per hour with forced air.I don't even think you would need a radiator fan for most setups. Then if you need a fan, just stick on a 12v universal radiator fan on there or if you don't need that much air flow or noise, stick a few computer fans on the radiator. For the line, I would just use air line. For he pump, I would just use a sureflo 12v diaphragm agro spray pump since it can pump pretty much any chemical concoction at 1 to 3 gpm.Last edited by mad welder 4; 08-14-2014 at 11:26 PM.old Miller spectrum 625 Lincoln SP-135 T, CO2+0.025 wireMiller model 250 and WP-18V torchCraftsman 100amp AC/DC and WP-17V torchCentury 115-004 HF arc stabilizerHome made 4 transformer spot welderHome made alternator welder
Reply:11ga is waaaaay too thick, I mean it'll work and all but damn...  I would use 18ga stainless.I've got a lot of info on DIY tig coolers on my build thread, a lot of other have popped up recently too.Welding/Fab Pics: www.UtahWeld.com
Reply:build thread:http://weldingweb.com/vbb/showthread.php...Cooler-for-TIGWelding/Fab Pics: www.UtahWeld.com
Reply:Mike check your inbox pleaseAWS 17.1, D1.1 and ASME IX (GTAW)Miller Syncrowave 350LX, Maxstar 150sth, Maxstar 200DX and  Millermatic 252 w/ Spoolmatic 30aMiller buzz box with Lincolin TombstoneThermal Dynamics Cutmaster 38
Reply:Originally Posted by MikeGyver11ga is waaaaay too thick, I mean it'll work and all but damn...  I would use 18ga stainless.I've got a lot of info on DIY tig coolers on my build thread, a lot of other have popped up recently too.
Reply:I built a Tig cooler 5 years ago by modifying a carbonator that I bought off Craigslist. I used the Proconn pump and the 2 gallon stainless tank that came on it and just re-plumbed and replaced the lines. The radiator is an aluminum transmission cooler that I attached to the side of the carbonator base and I added a sheet metal shroud with 2 muffin fans to force air through the radiator. The coolant temperature has never gone above 110 degrees during any of my aluminum welding since the cooler was built. I have used RV antifreeze and Distilled water 50/50 mix since the cooler was built with no problems. Adjust the pressure relief bypass of the pump to 45-50 psi and you will be fine. The 2 gallons of coolant seems to be more than enough.Charley Attached ImagesMiller MM252Miller Bobcat 225NTMiller DialArc HF / DIY Cooler2 Victor O/A TorchsetsMilwaukee 8" Metal SawMilwaukee Dry Cut "Chop" Saw 5 Ton Wallace Gantry Various Grinders, Benders, etc.
Reply:Originally Posted by Gravel1 cubic foot holds 8.34 gallons if I remember correctly.
Reply:Originally Posted by dva7.48 gal per ft^3
Reply:I've always felt that an old Cornelius keg would be a perfect reservoir for a cooler.   Stainless steel, opening to clean now and then, and you can cut and weld to make any size you'd like.  Pretty cheap as I recall (haven't home brewed in years).  Combine with one of those inline tranny coolers, the long round tubular ones with the radial fins radiating outward from the center.  Procon pump and motor.  Voila, a 5 gallon cooler for under $200.
Reply:Here are some rather large stainless tanks on CL. I'd like to see the cart some of the guys would build to move this around! http://houston.craigslist.org/bfs/4620689307.htmlGravelThe difference between theory and practice is that in theory there is no difference.
Reply:Originally Posted by Drf255I've always felt that an old Cornelius keg would be a perfect reservoir for a cooler.   Stainless steel, opening to clean now and then, and you can cut and weld to make any size you'd like.  Pretty cheap as I recall (haven't home brewed in years).
Reply:Originally Posted by GambleThat's a great idea. Then add a Y valve and circulate beer instead of coolant, and open the Y valve when you need a drink.
Reply:Originally Posted by GambleThat's a great idea. Then add a Y valve and circulate beer instead of coolant, and open the Y valve when you need a drink.
Reply:Here is one I built for a carbonator from Ebay. Stainless tank and AV evap from a auto.  drilled a hole in the end of the motor shaft and mounted a fan on it for cooling of the evap. Attached ImagesDIY CNC Plasma table USB BOB Price THCHypertherm 65Everlast PowerTig 255 EXTMiler 180 Mig13" metal latheMill/ DrillECT, ECT,
Reply:What torch are you running off that?Regards,RobGreat Basin WeldingInstagramBlue weldersRed weldersMy luscious Table DIY TIG Torch cooler
Reply:wp-18DIY CNC Plasma table USB BOB Price THCHypertherm 65Everlast PowerTig 255 EXTMiler 180 Mig13" metal latheMill/ DrillECT, ECT,
Reply:Originally Posted by CharleyLI built a Tig cooler 5 years ago by modifying a carbonator that I bought off Craigslist. I used the Proconn pump and the 2 gallon stainless tank that came on it and just re-plumbed and replaced the lines. The radiator is an aluminum transmission cooler that I attached to the side of the carbonator base and I added a sheet metal shroud with 2 muffin fans to force air through the radiator. The coolant temperature has never gone above 110 degrees during any of my aluminum welding since the cooler was built. I have used RV antifreeze and Distilled water 50/50 mix since the cooler was built with no problems. Adjust the pressure relief bypass of the pump to 45-50 psi and you will be fine. The 2 gallons of coolant seems to be more than enough.Charley
Reply:Here's the one I made. Used a trans cooler, Two box fans and a Procon pump. Homemade tank pictured.
Reply:I'm only an "apprentice", so what do I know? lol
Reply:Originally Posted by MCEHere's the one I made. Used a trans cooler, Two box fans and a Procon pump. Homemade tank pictured.
Reply:Here's where I am at. I sheared up 12 pieces 11 ga. stainless I got for free. I am got more than I needed just because it was free. I am making a tank that is 8" X 8".........this will give me approx. 2 gallon of coolant. I am wondering what and where to get the bungs and the filler cap. An idea on the cheap would be to weld a stainless nut big enough to tank a funnel and use a bolt as a filler cap. As far as the hose bungs go I was thinking again of welding nuts...........drilling out a bolt on my lathe........( basically a hollow all thread rod) and jam nutting it with about an inch sticking out to connect a hose to.Again any comments are appreciated.http://www.google.com/#q=stainless+weld+bungsGravelThe difference between theory and practice is that in theory there is no difference.
Reply:I found my some stainless bungs on Amazon, but I have some local places (hardware stores, but not big box) that have them too.Regards,RobGreat Basin WeldingInstagramBlue weldersRed weldersMy luscious Table DIY TIG Torch cooler
Reply:Can someone tell me what size/kind of fittings a Procon pump uses?
Reply:No but the shurflo pumps are 3/8" npt.The B size LH thread adapters from Western are here:http://www.brwtechnologies.com/mobil...ductCode=A-405Home depot sells 1/4" to 3/8" adapters
Reply:I have not figured out what sort of panel mount hose fittings will work though. I would like to oversize them to avoid any added circuit resistance.
Reply:That was the hardest part for me.Regards,RobGreat Basin WeldingInstagramBlue weldersRed weldersMy luscious Table DIY TIG Torch cooler
Reply:MikeGyver has some snazzy quick releases on his; I will dig back through the aluminum cart thread.
Reply:Originally Posted by atgI have not figured out what sort of panel mount hose fittings will work though. I would like to oversize them to avoid any added circuit resistance.
Reply:Originally Posted by GravelI like the idea. Keep in mind that yhe tank doesn't have to be big. 1 cubic foot holds 8.34 gallons if I remember correctly. The Miller ones I have looked at hold between 1 and 3.5 gallons.Looking forward to lots of good reference material here when I get ready to build one.
Reply:Originally Posted by Willie B231 Cubic inches per US gallon. A cubic foot is 1728 Cu In 1728/231= 7.48051948051 Gallons Any rectangular tank is in inches L x W x H /231= gallons. Cylinders is Radius x Radius x 3.1416 x length/231= Gallons.The one recommended for my Dynasty 280 DX is 1.3 gallons.The coolant used sells for $30 per gallon. Don't go with a huge tank. For a while I used sink water. My flow rate was about 3 gallons per hour. It worked fine. That's what Zapster's machine uses all the time.
Reply:Got the tank built today. Went 8" X 8" 11 ga. stainless. Worked out OK. I started walking the cup using 4043 1/16" filler rod..........switched to freehand.........ended up just freehand and fusing the corners. Using open corners this worked out well. The first pic shows all sides (except for the top) tacked on the inside this allowed me to fold up all the sides making things pretty accurate.The 3/8" bungs are actually a cast stainless pipe coupling cut in half.......worked out real cheap. The cap is a 3/4" nut and bolt. I am leak testing it overnight. Last edited by rahtreelimbs; 09-06-2014 at 07:43 PM.
Reply:Nice job! Sorry I haven't been able to talk. You can call me any time this weekend.GravelThe difference between theory and practice is that in theory there is no difference.
Reply:Looking good....**** if I can get some stainless sheet I may tackle this one too just for fun.Torchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:Looks great RTLTA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:Originally Posted by rahtreelimbsGot the tank built today. Went 8" X 8" 11 ga. stainless. Worked out OK. I started walking the cup using 4043 1/16" filler rod..........switched to freehand.........ended up just freehand and fusing the corners. Using open corners this worked out well. The first pic shows all sides (except for the top) tacked on the inside this allowed me to fold up all the sides making things pretty accurate.The 3/8" bungs are actually a cast stainless pipe coupling cut in half.......worked out real cheap. The cap is a 3/4" nut and bolt. I am leak testing it overnight.
Reply:It's the non-ferrous stainless filler rod. You've never heard of it? OP, sweet projectTeach Ag Mech - Mike At Home:Lincoln Electric AC225Miller Challenger 172Gas AxeWork:eclectic bunch of 90's vintage blue boxes
Reply:Originally Posted by dcoffmanjr4043 filler? Typo, or welding genius?
Reply:I have two coolers. One is a Bernard 2500 that I rebuilt. It has a radiator and a 6" electric muffin fan since the new Procon drive motor had only one shaft. The original motor had a fan with a dual shaft motor but it wore out so I just used the single shaft motor with a fan. It works great. My other one is home-built with ah 1/8" Wall SS tank. I made it too large (15 gallon) but I never run more than 5 gallons in it. It's also got a Procon pump and motor. There is no radiator and it has never needed one. You could weld all day with my Syncrowave 200 and ithe coolant would never even get warm. If I were to build another one, I'd make it no larger than about 5 gallons. That's all that you really need. I formerly used Miller Coolant but gave up due to the cost. Nowadays, I use distilled water with a quart of GM Dex Cool. I've yet to have a problem. There are pressure gauges on each unit and they run 50-60 psi. That seems to be OK since I've yet to overheat a torch in more than 15 years. I built the carts out of bed frames. The picture was when I was testing both units. I alternate them now and change them from time to time.Last edited by gnm109; 09-13-2014 at 08:02 PM.Miller Millermatic 252Miller Syncrowave 200Liincoln AC-DC 225Victor O-A Set
Reply:Originally Posted by GravelNice. I like the small footprint.
Reply:This is where I am at now. I have the the shroud mount built and the base as well as the tank. All I need now is the pump and motor.I am mounting this on a separate cart......this is the reason for the dinse and gas line connection on the front of the panel.I guess my aluminum welding is getting there..
Reply:I ran my machine for years on a total loss system.... I rigged a regulated water source, connected to the machine and out to the flower beds. I ran the water pressure at a point where discharge water was slightly warm when welding at a high setting.It worked fine and had zero issues.
Reply:Looks like a cool setup for a converting an small aircooled rig to liquid.
Reply:Lets say you have the sheet metal to make the liquid tank but have to buy everything else. How much time and $$$ is spent making your own?there are chineesse tig water coolers on ebay for $375, they are the same ones that everylast and longevity sell.Help me determine what savings if any are achieved by DIY?
Reply:You might want to move that fan out to were the blades are even with the shroud. The blade location were its at now; will make noise and chop air but not really move a lot of air. You could remake the bracket and flip the fan over so that the blades are level with the shroud since the direction of air flow make no difference.
Reply:Originally Posted by gmakraYou might want to move that fan out to were the blades are even with the shroud. The blade location were its at now; will make noise and chop air but not really move a lot of air. You could remake the bracket and flip the fan over so that the blades are level with the shroud since the direction of air flow make no difference.