My homemade portable welder

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Engine is a 1971 Datsun 74 cubic inch 70hp.  Generator is WW2 AIRPLANE Westinghouse 24volt 200 amp, my cousin used to weld with it back in the day, had it hooked up to a 25hp Wisconsin v4.  Main frame is 2x1 channel.  Got the engine mounts and generator mounts done today and started on the hoop frame to cover it all up.  I have a rheostat but will need to make an arc stabilizer for it.  Plan on also running an AC generator off the front and an air compressor, thus the mile of room up front of the engine, may shorten the skid a little, will see soon.  Here are some crappy pics I took with my cell phone.Last edited by MilitiaMetals; 07-15-2011 at 09:11 PM.
Reply:How well did the 25hp motor work? that generator should only draw like what, 8hp or so? How do you limit current? Got any details on the arc stabilizer you're going to build?Welding/Fab Pics: www.UtahWeld.com
Reply:Nice!That was my favorite little quasi-industrial engine back in their day.Man were they tough.Thanks for posting your project.Carry on!
Reply:The generator supposedly needs 15 or so Hp.  I chose my Datsun engine because it was rebuilt before I go it and is makes 70HP at 6000RPM and I only want to run it around 2500 to 3000(max)  Plus will also be driving a air compressor and AC generator, its for my service truck I use when I am custom FarmingI will have a rheostat to limit the current like other newer welders, just like an oven dial.  For the arc stabilizer I am going to use a 10 inch piece of round stock then wrap it with cloth tape(few layers) then wind 4ga enamel coated wire around it, doing 5 layers all insulated between each other.  The rod will be tapped at each end and mounted, thus grounded.  And then the arc stabilizer will be wired inline after my rheostat with a plug socket on the end to hook my stinger up.
Reply:Here is a head ache rack I made for my work truck.
Reply:Will paint it after I make bottle mounts for my cutting torch assembly
Reply:Pretty cool.
Reply:That is way cool!
Reply:Thanks!  The best part is I got the generator for free from my cousin!!  He said take it, because the Wisconsin v4 was worn out and it had seized from sitting inside his shop.  I later found another generator the exact same!!!  Was my neighbor down the road from our farm, he bought it 20 years ago from an auction, they had been using it to run drills and other brush type appliances, so it was never set up for welding but its like new! Paid $25 for it!
Reply:ok, nice...i must admit...it passed my standard...good job!
Reply:lol what exactly are your standards? were you expecting less lol?
Reply:I will bend another hoop for the front and cover it all with 18ga sheetmetal.  Will have to hooks on top to lift it into my truck with a tractor, this puppy is pretty heavy lol.  Have to pick up a rad for it tomorrow, going to use a military surplus gas can for a fuel tank.  Have not decided whether or not to run an electric fan or the manual one.  Any input on that? Have to order a drive pulley too, and then weld a shaft to the flywheel, should be fun, It's going to involve some lathe work, good thing I have a machinist for a cousin!
Reply:repeat woops
Reply:I learned to weld with one of those that my dad built right after he got out of the army.  World war two. The one he had, had two large posts and two small posts for electrical hook up.. the large posts were hooked up to the ground and the electrode.  the two small posts were hooked up in series with a potentiometer. that fed 12 volt to the field windings. When you fed the field more power your arc got stronger. He also had some kind of large cast iron resistor that got quite hot. Mac
Reply:Neat!  I have been told by other welders and have learned myself, nothing welds better than dc, I think I am going to love this thing!
Reply:Have the catalog from Master Mechanic in 1950's that sold the surplus  stuff to build them . The yellow transformer welder I have the catalog for that too , built in Canada !!!  John
Reply:Originally Posted by MilitiaMetalsI will have a rheostat to limit the current like other newer welders, just like an oven dial.  For the arc stabilizer I am going to use a 10 inch piece of round stock then wrap it with cloth tape(few layers) then wind 4ga enamel coated wire around it, doing 5 layers all insulated between each other.  The rod will be tapped at each end and mounted, thus grounded.  And then the arc stabilizer will be wired inline after my rheostat with a plug socket on the end to hook my stinger up.
Reply:Its the origional rheostat that came with the generator, and yes it is big lol.  Is there something I can use instead of my homemade arc stabilizer?  I am going to a local landfill to pick up scrap metal tomorrow.  Maybe there is something I should look for?  Thanks for the compliments and tips everyone!
Reply:Here you go MM... The original plans for building that 200A welder using that airplane generator from the 1940's.... Nothings changed since then except you're using a stationary engine instead of putting it under the hood of your truck.http://www.vintageprojects.com/metal...oArcWelder.pdfThis gives the plans for the arc stabilizer as well as photos of the one they made... Good Luck BTW.... Those generators were state of the art back then and should function just fine now too.If I had one I'd build one too.
Reply:That's strange that they tie the inductor core into a frame that loops back around to the other end of the core. This turns it into a transformer (without a secondary) instead of an inductor. Inductors store energy in a magnetic field in the airgap from one end of the core to the other, transformers ideally store no energy but rather transfer it as efficiently as possible between coupled windings. Seems like it defeats the purpose, it should perform better not being tied together... something to consider in your experimentation anyway.Last edited by MikeGyver; 07-16-2011 at 05:35 AM.Welding/Fab Pics: www.UtahWeld.com
Reply:Here are some mock up photos, will not be working on it until August 1st, goin on holidays!I am going to run flange bearing on the tranny input shaft to keep it dead center and take away the sideplay.  Will have to get it machined and a sleeve put on the shaft to make it longer.
Reply:I put air shocks on my old chevy today, so she can handle the extra weight of the welder, what a difference in height!
Reply:Cant wait to see  this   finished .   Are u gonna put  a sheet metal  cover  around it all  ?>Innovations are what i leave behind for History
Reply:Definitely! She will be covered up and painted!  Pardon my crappy microsoft paint skills
Reply:Congradulations on your welder design and build. The aircraft generator may be considered to be stone age technology, but then again; diamonds are stones.I offer three choices: Good, Fast, & Cheap. You may pick two.Hobart AC/DC StikMate LXHarbor Freight AD HoodHarbor Freight Industrial Chop SawDeVilbis 20 Gallon, 5 HP CompressorThank you kindly!
Reply:Here is a rough sketch, not to sure where I am going to put my control panel with the gauges and such yet.
Reply:Why not put the gen head under the motor, may be more compact.Tim Beeker.
Reply:It would be way to tall, not enough room to clear the oil pan
Reply:Plus it will be more stable with the L shaped frame in the back of my truck.  And I figured there would be more room under the engine for better air flow since I am covering it up with tin
Reply:Originally Posted by MilitiaMetalsHere is a rough sketch, not to sure where I am going to put my control panel with the gauges and such yet.
Reply:I don't quite understand what you are saying,
Reply:This image might be protected so I'll include a link rather than post it.Look at the direction of rotation.  One run of the belt is tight and one is slack.  Lots of engineers get this mucked up so don't feel bad.With the slack on top gravity will keep the belt wrapped on the shieve for better grip.http://4.bp.blogspot.com/_e_e1W8RlFC...400/pic017.gifGordie -- "I believe you understand what you think I said, but I'm not sure you realize that what you heard is not what I meant."
Reply:Originally Posted by Nitesky...Look at the direction of rotation.  One run of the belt is tight and one is slack.  Lots of engineers get this mucked up so don't feel bad.With the slack on top gravity will keep the belt wrapped on the shieve for better grip.
Reply:I don't think it will matter too much eh?   Gonna run 2 or 3 belts, but thanks none the less
Reply:Although "top slack" in a belt drive may have some advantage, I don't think it takes precedence over what's most  practical for a given drive's overall design.I guess I understand the theory, but except for very heavy or long belts, or maybe flat belts (threshing machine?) otherwise I'm not sure how significant "droop" would be on a short and tensioned V-drive.I don't recall ever reading drive engineering data that put a preference on the slack side's position. Good LuckLast edited by denrep; 07-19-2011 at 04:32 PM.
Reply:Kudos on the welder build!Buy American, or don't whine when you end up on the bread line.
Reply:Thanks guys!
Reply:Man I've got to see this completed. We need video as well! Awesome!
Reply:Now thats a project that will get you some bragging rights. Nice work, man!! [Account Abandoned 8/8/16 Please Do Not Attempt Contact Or Expect A Reply]. See you on YouTube! -ChuckE2009
Reply:I have built one of these welder a 400 amp job and have been around 3 others. It was fun to build but had trouble with my gen had to send it back.I got it from surplus center. Worked on it on and of most of one summer. They have tec guy thier made several call to them one of them told me belts are sliping go to chain.That fixed it. It was a very hot welder. Used mazda engine at first then found contintal same as on sa200. If I had lots of time I would build another one. But they are very hard to weld with and thier is very little control of heat throttle and reastat used together.
Reply:Wow bin busy running my scrap metal business and custom combining and trucking, finally got back to work at the welding shop and have put in a little more time on my welder, here are some updated pics.
Reply:Where in Saskatchewan are you? That's a super cool project I would love to see how it welds when its done.
Reply:I am 2 hours south of Saskatoon.  Thanks for the compliments, much appreciated
Reply:put some diamond plate on it, mocked my rad up and am gonna mount my generator a little differently to lose some girth on the ole girl
Reply:Interesting.We are on our way to being farmers! Our site is always under construction so check back often for updates.  http://www.philosophyfarmstyle.com/
Reply:I put my gen beside engine like you are but it is unhande to haul. I thout I would run a long shaft out of engine and put gen on top of shaft but a got better welder and sold it. A friend of mine has got 2 gens lately a 200 and 300.300 are more rare.  Good luck.
Reply:I would have loved to have found a 300, I did however manage to get the one for free and another 200 for $25!  So I might make another portable welder for my father after I finish this one.  But I do not think I will need such a big engine, I would use just a 25hp as I only need to run a welder on the next one.
Reply:The one I built was 400 it was very hot. I found some rods at work that are 400 amp shop welder would not burn it had no problem.I wish I could remember what they were took to hands to hold stinger.I think you well be happy with 200.My buddy is going to use a 16 hp on his 200 I think.
Reply:Wow, what a way to get 'er done!Proud to support Reliable Sheet Metal Works, in Fullerton, CA.Full service sheet metal fabrication serving Orange County since 1926.http://www.reliablesheetmetal.com