Crossing that bridge - big spool to little spool

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Post #35 says Originally Posted by MonicaI know this is an older thread but I needed to followup for the readership as I've had time to work in the garage again.  I replaced the 10lb spool with the 1lb and the machine is working fine.  WFS I got set again as well.The problem was the 10lb spool as suggested and confirmed.  The WeldPakHD will not run a 10lb spool.I've got the10lb stored and I'll cross that bridge when I get there on transferring the wire.Thanks yall.
Reply:Take a look at Denny's (Yorkiepap) posts. He's posted up his setup for respooling small rolls from larger rolls in the past.Edit: found it for you. The one handed thing might prove to be a challenge, keeping the two from unspooling when done after you cut the wire..http://weldingweb.com/vbb/showthread.php?t=16409Last edited by DSW; 09-05-2011 at 11:59 AM..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Excellent- thank you.  I was thinking of a similar holding jig, a rod on each side holding each respective spool.  The motor power I thought I could use is the hand drill.  Put it up to the empty spool rod and wind away.  Obviously there's details in there but doable.For wire cutting and holding tension, maybe can use two clips of some sort, positioned in between the distance of the spools where the wire passes.  Before cutting the wire I attach each clip to the wire so it holds tension on each spool, then cut the wire in the center of the clips.  That will allow me to deal with each spool one at a time.Lincoln AC225 and CartLincoln WeldPak HD and CartOne hand
Reply:I was looking at Yorkiepap's contraption on the other thread.  For wire holding how about two raised platforms that are near the wire.  Just drop a strong magnet on each platform to trap the wire, then cut in between the platforms.  Then grab each wire pull it out from under the magnet and tie it off.You could also make a permanent wire guide/holder on the large spool side and just never remove the large spool from the contraption.Last edited by AndyA; 09-05-2011 at 01:33 PM.Dynasty200DX w/coolmate1MM210MM VintageESAB miniarc161ltsLincoln AC225Victor O/A, Smith AW1ACutmaster 81IR 2475N7.5FPRage3Jancy USA1019" SBAEAD-200LE
Reply:We have made several rollers on the job site to help roll up all sorts of materials and such.I was actually going to make one for the house out of SS to wind up garden hoses on different reels.Having made rollers in the past, I see a few things to keep in mind.If for any reason you stop winding, the large roll will have a tendency to keep going. You could use one hand to stop it or incorporate a break or something to apply resistance on the roll.From his pic, it looks like he might not have that issue since the inside angles look to be snug on the sides of the roll.The other issue would be getting the wire evenly rapped across the roll so you dont experience any binding during use.Just some food for thought.When I design something, at first I always over engineer it to keep the engineers/safety department happy. Then go back over it with the K.I.S.S method prior to submitting it for approval.I wonder if he experienced any binding issues when he used those rolls.Semper FiJesus may have been a Carpenter, but his dad was a Millwright" A grinder and a can of paint, will make a welder what he aint' "I've done so much, with so little, for so long, that now I can do anything with nothing!
Reply:skelly, excellent points to keep in mind.  I think resistance on the big spool will help that roll over affect.  I work with leather and I've got a stitching machine that I wind bobbins for so being familiar with the cocept should help the success rate.I found a pretty simple setup on youtube here:[ame]http://www.youtube.com/watch?v=3bTcN1ZXvEc[/ame]Lincoln AC225 and CartLincoln WeldPak HD and CartOne hand
Reply:Monica I like it. Nice and simple. Thanks for posting the vid. He seemed a little uncomfortable, being right handed maybe he should have switched the rolls around.Let me know how it works out for ya.Semper FiJesus may have been a Carpenter, but his dad was a Millwright" A grinder and a can of paint, will make a welder what he aint' "I've done so much, with so little, for so long, that now I can do anything with nothing!
Reply:IMNSHO, skip the rewinding or transferring wire from one spool to another smaller spool.Just make a small external rack and put the big spool on that.  Add a little bit of friction on the big spool so it doesn't unwind or over-run (same way that the existing 'internal' spools have some frictino/drag on them to keep from unwinding or over-running).  Put a small hole in the sheetmetal case in the appropriate place for the wire to unwind from the external spool and then go into the drive rollers.  Done.  Just don't end up pulling the machine away from the external spool or changing the 'alignment' between them (put them both on the same cart/platform or mount the external spool frame off the back end of the machine itself.And be aware that the spool of wire will be 'energized', so don't short circuit things out (to the work or to the case/sheetmetal of the machine).  The best laid schemes ... Gang oft agley ...
Reply:Originally Posted by MoonRiseIMNSHO, skip the rewinding or transferring wire from one spool to another smaller spool.Just make a small external rack and put the big spool on that.  Add a little bit of friction on the big spool so it doesn't unwind or over-run (same way that the existing 'internal' spools have some frictino/drag on them to keep from unwinding or over-running).  Put a small hole in the sheetmetal case in the appropriate place for the wire to unwind from the external spool and then go into the drive rollers.  Done.
Reply:Hmmm, I -thought- that the little WeldpakHD wouldn't even fit the 8-inch (10-12 lb) spools.  Hence her problems.And I thought this all sounded faintly familiar ... yup, I posted my same opinion/idea back in her other thread too.  (the drive motor on the 'smaller' machines just runs the drive rollers AFAIK.  The wire spool just has to fit inside the space and have the 'proper' adapter(s) to fit and have the appropriate drag/friction put onto said spool say it doesn't unwind or overrun.  YMMV  I know that my small Lincoln's don't drive the spool itself and just drive the drive rollers, as I have sometimes 'opened' the drive-roller 'latch'  and hit the gun trigger to purge the gas line and not feed any wire out.  Gas flows, line is purged, no wire comes out, just as desired.  Flip the drive roller pressure arm back and get onto the welding.)  The external wire spool holder is on my ToDo List.  I think I have the 2 inch spool 'post/spindle' and some miscellaneous parts/pieces and some various steel scraps, but so far I have been just been using the 8 inch (10-12 lb) spools on my machines.  Drill a hole, put in a rubber grommet, make an small external frame/holder, go to town sounds easier than trying to wind wire from one spool onto another (you'd still have to make or rig up some sort of external spool frame/holder there anyway, with some drag/friction so it all doesn't unravel or overrun as you wind wire from the big spool onto the small spool).The only time I can see absolutely having to have the wire on the little 4 inch (1-2 lb) spools is for a spool gun.Again, YMMV and .  The best laid schemes ... Gang oft agley ...
Reply:Originally Posted by DSWMoonRise, I believe her problem was that the Weldpak HD's drive motor doesn't have enough power to pull a full 10lb spool. The manual lists it being capable of using up to 2lb spools if I remember the thread correctly. the 10lb spools fit, but the machine didn't feed well with one installed.http://weldingweb.com/vbb/showthread.php?t=44724
Reply:Try that simple rewind method.If you try to pull on the large spool and you get to much friction it can damage the cast aluminum drive shaft (if yours has one).Then you are looking at another repair Last edited by skelley521; 09-06-2011 at 01:38 PM.Semper FiJesus may have been a Carpenter, but his dad was a Millwright" A grinder and a can of paint, will make a welder what he aint' "I've done so much, with so little, for so long, that now I can do anything with nothing!
Reply:Did a little jerry rig and got about half the little spool done and decided to cut bait and get to work on finishing up the pieces I have to weld.  I need to get that project off the floor like yesterday. We'll see how it unwinds.  When this runs out I have a clue on what I can do for the next respool.Ok, back to work.Lincoln AC225 and CartLincoln WeldPak HD and CartOne hand
Reply:Finished up half hour ago.  Things went fine.Lincoln AC225 and CartLincoln WeldPak HD and CartOne hand
Reply:Nice, thanks for the update Semper FiJesus may have been a Carpenter, but his dad was a Millwright" A grinder and a can of paint, will make a welder what he aint' "I've done so much, with so little, for so long, that now I can do anything with nothing!