Converted Lotus Tig pedal to TA185 machine

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I have a Thermal arc 185 AC/DC inverter tig welder. They want close to $300 for a foot pedal by the time I pay for shipping. .Not gonna do it! I'm not sure if I made a mistake buying a Lotus foot pedal off of Ebay for $69+ shipping . It seems to be of a pretty good qaulity for the price. The pins dont match up but I got in touch with Tyco electronics and found a matching male plug that will fit the welder, #206434-1.The pedal that I purchased has a 5K OHM pot that has 3 wires conected to it(red-yellow-green). Has a on/off pedal switch with 2 wires Black and Brown. TA185 AC/DC tig welder diagram: Pin# 1........chasis groundPin# 2.......contactor control/+24VDCPin# 3.......contactor control/GNDPin# 4....connected to pin #8Pin# 5.......potentiometer maximumPin# 6.......potentiometer minimum(GRN)Pin# 7.....Center amperage control wiper 0-10 VDCPin# 8.....connected to pin#4Recieved my electrical parts today for my Ebay bought Lotus 5K OHM tig pedal for my TA185. Gathered my tools and went to it.Digi-key.com)Part #A1028CT-ND (.04)1MM 18 AWG Gold pins, I had to use a magnifying glass with light to really pay close attention to solder joints. The gold pins accepted the 16/18 gauge wire and solder nicely.1. First I cut back the required amount of wire. 2.I made a small jumper wire to solder to pins 4 and 8 with a shrink tubing. 3. I pushed the two pins securely into the numbered holes 4 and 8 into the connection plug #A1371-ND. I made sure they were bottomed out to have the right length on the opposite side.4. I then proceeded to solder the other 5 pins to the wires5.I inspected each wire and pin solder joint for any flaws in the joints.6.I then sliped the outer shell #A1330-ND onto the main wire for later connection.7.I then slipped the main wire shrink tube (3/8" ID)onto the main wire and pushed it down a good ways out the way for now.8.I cut 5 1" 1/8" shrink tubing and slid them over the 5 wires.9.I pluged the 5 pins into the connection plug #A1371-ND into hole numbers 2-3-5-6-7.10.2-black 3-brown(contact switch wires. 5-green(max pedal) 6-red(minimum pedal) 7-yellow (center pot wiper arm).11.slid the 5 heat shrink tube onto the pins and heated with lighter to shrink.12.slid the 3/8" shrink tubing down over all the smaller wires and heat shrink tubing also heating it up shrinking it around the main wire too.13.I slid the outer shell(strain relief)#A1330-ND on to connector and tighten into place.14.Finnally I clamped the connection to the main wire. Attached ImagesLast edited by cmartman46; 08-21-2009 at 12:56 AM.
Reply:more pics Attached Images
Reply:.04(1mm) gold pins.16/18 AWG Attached Images
Reply:$69.00...Lotus inverter tig pedal$13.95 USPS priority large flat shipping$5.21...Digi-key #A1371-ND 8 pin connector.$2.90...Digi-key#A1028CT-ND gold solder pins$4.31...Digi-key.#A1330-ND connection relief clamp outer shell$4.95..shippingTotal=$100.32Already had solder and heat shrink tube.Next is the test run and see if it was worth $100.00
Reply:Looks good.  I'm sure it will work.  I brought the TD unit because i was in a hurry for it and didn't have the time nor patience to look at other options.I must say that it is a very well built unit of all metal construction with stick on grip tape like a skateboard.  The cord is of very high quality and super tough with an overlay bit at the pedal end to stop too much flex.good luck and happy pedalin'.Forgot to mention  that it cost me $700AUD 2 years ago but they have come down a bit in recent times.Last edited by LarryO; 08-21-2009 at 03:18 AM.
Reply:Thanks for the nice reply.I'm curious? What cost $700?The pedal or TA welding machine?If you did'nt already, check out "made in china.com" and type in tig welders.I did'nt know Miller,Lincoln ect welders were built there? A good way to make some $$$$$$$.Thanks!
Reply:i got the SSC pedal but i think it was more than 100.00. the price for TA parts is outrageous.300.00 for  adigital amp meter.........insert thoughtful quote from someone else2000 Thermal Arc 300GTSW 3.5 hours1946 Monarch 20 x 54 Lathe1998 Supermax 10x54 Mill2004 Haco Atlantic 1/2" Capacity Lasernot mine but i get to play with it
Reply:We had a coil ground out in our thermal arc and it set us back 600 bucks.  I think one of the guys was banging it around too much.  And speaking of foot pedals.... I took it out in the field to weld up some aluminum irrigation pipes.  It wouldn't arc hot enough so after 30 minutes of screwing around with it, I had to wrap things up and head back to the shop(not good with the customer standing over your shoulder).  It turned out to be the cable inside the plug had twisted up and was shorting out the pins that run to the potentiometer. Fortunately it was an easy fix.Common sense in an uncommon degree is what the world calls wisdom.
Reply:That was $700AUD for the pedal at the time.A new TD 200 TIG welder costs about $4700AUD at the moment
Reply:I tested my new Lotus tig pedal on my TA185 after wiring up the right plug.I am very satisfied with the control and feel of the pedal and have to say it was worth the research and time to order the right parts.I finnally got to weld a beer can. I did have a slight breeze blowing while welding under my carport testing my pedal out. Attached ImagesLast edited by cmartman46; 08-23-2009 at 01:50 AM.THE OLDER I GET! THE  SMARTER MY DAD WAS!Thermal Arc 185 inverter Tig welderABITIG 26  tig torchLotus foot pedalLincoln 225 stick welderClark 185SG Mig spoolgunwelderVictor torch/regulatorsHF36" shear,bender,roller.
Reply:This is the plug that came with the lotus foot pedal. Attached ImagesTHE OLDER I GET! THE  SMARTER MY DAD WAS!Thermal Arc 185 inverter Tig welderABITIG 26  tig torchLotus foot pedalLincoln 225 stick welderClark 185SG Mig spoolgunwelderVictor torch/regulatorsHF36" shear,bender,roller.
Reply:Very nice!  I need one of these myself and at just over $100 it seems like better money spent than $300 for a new TA control.  Got another one laying around, lol!Chris Allredwww.UnusualFabrication.com
Reply:What welding machine do you have?I never heard of it done but the other day I was at my buddy's house and telling him about my Lotus pedal I bought off of ebay and how I put another plug to fit my TA185 for tig welding. I showed them the beer can I welded, his wife said that she uses a pedal for her sewing machine for different speeds. I would think that a sewing machine pedal might work. But that would be another project that would have to be researched and see what's inside and to see if it's compatible.2 switch wires on and off, 3 potienometer wires 5K ohm..Thanks to the guys on here I saved $150 or so on my pedal doing it myself.Good luck.THE OLDER I GET! THE  SMARTER MY DAD WAS!Thermal Arc 185 inverter Tig welderABITIG 26  tig torchLotus foot pedalLincoln 225 stick welderClark 185SG Mig spoolgunwelderVictor torch/regulatorsHF36" shear,bender,roller.
Reply:Hey cmartman46.How do you like your Binzel torch?Just ordered another with lower amps and smaller head.Found a lot of torches dont fit my Cigweld Trantig 200 AC/DC (TA 200) The gas hose input to the DIN connector seems to hit the right side of the body before its fully engaged.Binzel make the OEM torch here in OZ for the Cigweld machine.I think the quality is a lot better than most.I like the ball end where the cable exits to help cable pivot.
Reply:I was used to using a watercooled weldcraft 300amp head with gas lense and #6 alumacups and short back caps to get in tight places to weld.. The aircooled abitig26 torch head that came with my TA185, is alot more bulky compared to the previous mentioned torch. But I am getting use to it for now. And like you said, I also like the swivel feature. I did'nt take it apart yet but I know it takes a super small torque head bit to disemble the unit. I have a set of torque bits but still too big for the torch screws. I might have to order the bit from TA.I appreciate your info on the OEM units.Thanks.So good so for..THE OLDER I GET! THE  SMARTER MY DAD WAS!Thermal Arc 185 inverter Tig welderABITIG 26  tig torchLotus foot pedalLincoln 225 stick welderClark 185SG Mig spoolgunwelderVictor torch/regulatorsHF36" shear,bender,roller.
Reply:It takes a T6 torx bit for the abitig 26 torch .THE OLDER I GET! THE  SMARTER MY DAD WAS!Thermal Arc 185 inverter Tig welderABITIG 26  tig torchLotus foot pedalLincoln 225 stick welderClark 185SG Mig spoolgunwelderVictor torch/regulatorsHF36" shear,bender,roller.
Reply:I found this information very helpful when I wanted to make an adapter to use my Miller (14-pin) finger remote to work on my Thermal Arc (LS300) welder.  I checked with Thermal Dynamics about making a pin-to-pin and to verify the pot ohms are compatible.They verified that Miller uses a 1k ohm pot and this should not be a problem with Thermal Arc (TA) LS300’s remote (input) once the adapter is used.  I’ve listed the part numbers from manufacture and from Mouser electronics  part numbers and prices and pin-to-pin configuration for any other people who wish to make the 8-pin (TA) to 14-pin (Miller) adapter.  Thermal Arc makes this part if you want to pay $116 (Welding Supply.com) part # 10-4003Miller 14 pin (female) parts (Amphenol  )                                                                                                                      (Mouser Electronics #)97-3057-1012-1                                                                                                                #654-97-3057-1012-1Amphenol Circular Mil / Spec Connecter clamp w/ bushing size 20, 22                      $ 8.99     97-310A-20#654-97-310A-20Amphenol Circular Mil / Spec Connecter sz 20 Recept Shell In line$15.0497-20-27S#654-97-20-275Amphenol Circular Mil / Spec Connecter 14P Socket Insert Shell Size 20$10.57Thermal Arc 8 pin (male) parts1-206062-4#571-1-206062-4TE Connectivity Standard Circular Connecter STD Cable Clamp $5.5766570-3#571-665703TE Connectivity Standard Circular Connecter SODER PIN CNT 18 (Quantity 8 @ $0.26/each)  $2.08206434-1#571-2064341TE Connectivity Standard Circular Connecter PLUG REVERSE 11-8$6.70Here are pin-to-pin match between Miller’s alphabet (14-pin) and Thermal Arc’s 8-pin numbered:Thermal Arc 8 to Miller 14 pinPin 2 = APin 3 = BPin 5 = DPin 6 = CPin 7 = ELast edited by lo7us; 04-27-2012 at 12:48 AM.
Reply:Good job man! A little research can save alot of money and be very satisfying.Some things look harder than they actually are but I always do my homework on things I never done before.  It's been a while since I've been on here. 2 1/2 years ago I landed a job programming and operating an ABB robot buiding (welding) Utility vehicles. I never seen a welding robot in person before but I accepted and assumed the responsibilities that go with operating  the robot. I got frustrated trying to understand the language but stuck it out. After three months I was getting more proficient. Having welding,computer skills and radio control back ground helped big time. It's been about 2 years since setting up my foot pedal.  I went play with my Thermalarcmaster 185 the other day in my shop and tried new settings for welding very thin aluminum (cheap beer can)  "LOL" here's the result on my first try. Good luck and thanks for the reply. Keep me informed of your set up. Attached ImagesTHE OLDER I GET! THE  SMARTER MY DAD WAS!Thermal Arc 185 inverter Tig welderABITIG 26  tig torchLotus foot pedalLincoln 225 stick welderClark 185SG Mig spoolgunwelderVictor torch/regulatorsHF36" shear,bender,roller.