portable welding?

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I have been looking at mobile/portable welding set-ups as i would like to purchase one relatively soon...i found this site, www.zena.net and was wondering if anyone on this site has ever used one of there machines and if it is worth the money? Also if anyone has a good experience with a mobile welder if you could let me know what you are using it would be greatly appretiated!-->amazing what a 1.3L can do
Reply:I use the miller maxstar 150 for mobile tig welding, Steel and SS. I have a lincoln 100 mig for mobile mig jobs. A buddy has a truly mobile mig welder, runs off the truck battery. And, there are several lighter weight stick welders that run on 110v to make mobile welding easier.
Reply:I am dating myself but during post WW2 Prairie farmers would purchase war surplus aircraft generators and drive them from tractor PTOs and vee belts.  These units you are looking at are the multi generational offspring of this idea.  I don't know anyone personally who has used these alternators for welding however the limiting factor was the ability of the vee belts to carry enough power to the old generator.  I considered making up one of these units from parts in the '70s and a retired prairie farmer I befriended suggested at least double belts and a crankshaft extension with an outboard bearing block for support.   You might notice that the larger welding unit takes double vee belts.  Also front crankshafts on automotive engines are not designed to take heavy side loads.  Excessive side loads can shorten the life of the front main bearing if the main bearing is not large enough.  This is no problem if you are using the arrangement for short periods but could be a problem if you are welding eight hours a day.   These alternator units have to spin a very high speeds so the belt has to turn over a relatively small diameter at the alternator end.  I looks like a good quality design for use on a service truck. It seems to be well thought out.  The price reflects this.   You might consider looking around on the Internet.  There were places that had free plans for alternator welder using standard alternators upgraded to take the load and give a smoother DC arc.  It will give you ideas as to the practicality of a commercially made unit or a home made unit.
Reply:I looked into buying a Zena set up. I didn't like several things about it. Last time I looked at the Zena it was little more than a converted late model alternator. I've seen so many late model alternators burn from nothing more than jump starting a car with a completely dead battey it makes me wonder how long one of these thing would last. To compound this problem most of my work would be close to maxing out a zena capacity. In the past I've seen several articles on the net for free or small charge detailing how to convert an alternator into a welder. You might want to try that and see how long it will last. I have no doubt that zena has the best handle on the details of converting an alternator into a welder and controling it. In my opinion it is something best left to a piece of emergency welding equipment rather than a welder that can be counted on for years of trouble free use. Will a zena put out 120 volt AC while welding, not the last time I looked. Will a zena put out 240 volt AC if needed, I don't think so. If you install a zena on a pick up truck don't you still need some sort governor or high idle set up for the pick up? To me it all comes down to how you intend to use it. For emergency use it's probably the best on the market. For every day use one a portable welding truck I'd go with a machine made for the job.
Reply:thx for the reply's guys so far i havent heard anything good about the alternator set-ups either on or off the forum so i dont believe i will be going down that road. And rojo im not to sure what you are using to power your 150 and 100 im guessing just outlets. But i think im looking for more of something where im totally mobile. Does anyone have any experience with the bobcat 250?Last edited by rotaryrocket; 12-24-2006 at 01:54 PM.-->amazing what a 1.3L can do
Reply:If you want a good alternator, look into the Leece NeVille 300+ amp units from firetrucks. You can regulate the output voltage with several simple regulators.
Reply:Originally Posted by rotaryrocketthx for the reply's guys so far i havent heard anything good about the alternator set-ups either on or off the forum so i dont believe i will be going down that road. And rojo im not to sure what you are using to power your 150 and 100 im guessing just outlets. But i think im looking for more of something where im totally mobile. Does anyone have any experience with the bobcat 250?
Reply:what is the comparisson price between the ranger 1000 and the bobcat 250? are the stats similar?-->amazing what a 1.3L can do
Reply:I have a Zena.  I am quite satisfied.  I have used it for 2 yrs, no problems.  I Don't use it daily, however.  I converted from a portable engine driven welder to the zena, because the engine driven welder was dead weight in my truck more than it was used.  I carry a inverter and attach for my electrical needs.  Together they weigh about 25 lbs as opposed to 300+ lbs for engine driven welder.  Mine is attached under my truck hood.  However, I am sure that it would run well as a free standing welder.  It is 100 percent duty cycle at 150 amps DC ,also.  With some creativity, I am sure one could make a great genset and save weight and money. My Zena is electrically isolated.The only thing I thought would be a negative was the fact that the controls were in the welding electrode.  I thought the durability would be an issue, however I have had no problems.Check my posts,  I have posted on it a couple of times.  I wanted one for years, Though I listened to the negatives from people who hadn't used, then purchased a engine driven welder.  Finally after I wore my engine driven welder out and being tired of the space and weight occupied by the unit, I bought a Zena.   I would like to hear negatives from those who have used it.I probably wouldn't purchase one just for home use.  However, It works well for my business. I got mine from Zena off ebay $450.  The company occasionally sells there.
Reply:which model are you using? and what are you mostly using it for? any pics? and how was the installation? sorry for all the questions but you are the first one that has parsonal experience with one. -->amazing what a 1.3L can do
Reply:rotaryrocket,There is some more info over at the Hobart forum about this topic.I did a search for "zena" and got a few hits.  link, and link.Hope this helps.-Razer
Reply:Lincoln Ranger 250 is around $3000 not sure about the Bobcat probably around the same maybe a little cheaper.  I like red though.DewayneDixieland WeldingMM350PLincoln 100Some torchesOther misc. tools
Reply:My Zena is mounted under the hood on my Ford Ranger.  I use it for any remote welding where electricity is not available.  I do gate repairs, steel stairs and trailer repairs.  Electricity is useually available for railing work.  I have the 150 amp model.I also got the idle speed control.  I purchased the add-a-pulley, it is mounted above the alternator.  These purchases were made after initial installation.  Though I would suggest getting everything at time on initial installation.  Installation is quick and simple.  You need to make or buy a mounting bracket and purchase a belt.  The add a pulley is need for reducing engine rpms and mounting to another device in the vehicle.  The largest installation problem, was purchasing the correct length belt.  Autozone finally invited me behind the counter to pull my own belts off the shelf.  Since there is not much adjustment in the way I mounted the welder, I needed a belt that had to be froced on and then adjusted.The only thing I dislike about the unit is the additional wire necessary to connect the electrode to the control.  I fabbed my own extension cables and the control wire.  The connections were available at my local electronics store.  I don't think I saved any money fabbing my own cables.  My extension cables are just over 100 feet each.  I keep the stock 20 feet cables with electrode holder and ground in my truckbox.The long electrode holder is no problem-keeps your hand farther away from the arc.  The push button start is great-eliminates unintensional arc.  The electrode also has proven durable.They are selling one on ebay.  I contacted several customers on ebay prior to purchasing mine.  I got no negative responses, though some had not hooked up the unit.For some reason the attachment button is not working so I can't load any pictures.  I try later.
Reply:wow some good info,and links thx guys!-->amazing what a 1.3L can do
Reply:TAPWELDER....You said someone would have to fab their own mounting bracket... so I take it the application is NOT vehicle specific. Well before I dump out a ton of questions I'll check their site first...... I own several engine drives but sometimes I don't want to lug a trailer around, especially if it's an in and out job..... to say the least my curiosity is peaked._________________Chris
Reply:I would just like to add something (else)...In the first link I posted, a poster says that while the Zena alts do look like auto alts, its is an "alternators case with the guts removed and completely replaced" with "high performance welding components".  Uh... are those the "high performance welding components" that give the 40% duty cycle we all know and love?.   as compared to the normal 100% duty cycle we see on auto alts??  I call BS!  (I do not doubt the poster's sincerity, just correctness.)  An alt consists of about 5 or 6 things; stator, stator windings, rotor, rotor windings, and diodes, and sometimes a voltage regulator.  What are they going to replace?  The alt diodes and stator windings are rated at some amperage in a vehicle and that will be at 100% duty cycle (not like this BS we put up with with welders that are not capable of operating continuously!) Get an alt rated at 130 amps it it will be capable of that, and it will not know what it is powering. Seriously, nothing against Zena, but I don't see that you are getting much beyond a packaged system rather than having to piece it together yourself.  One nice thing is that  it appears to come with a solution for controlling the engine rpm (something that you will have to do if you whip this up yourself)  Some people like packaged things, others prefer to whip it up themselves.Take your pick.I picked up a 130 amp ford/3g/bosch/motorcraft alt at a local auto recycler for $26 out the door (they pulled it).  Car-Part.com is your friend.  Select:1997, Ford Taurus, alternator, select the area you wish to search in, and click SEARCH.  When it asks you to select a specific model, select "6-183 (3.0L), OHV, 130 amp" (the top one), and click SEARCH.  Go to the bottom of the page and click on the page number with the asterisk on it and it will show you the lowest priced one in the search area.  With that, you lose 20 amps, and have $974 left to install it yourself.I welded using a denso that I got a while ago that I had floating around the shop, and it just happened to fit in my car.  It was only rated at 90 amps (if the same as my car) but it cut a nice hole in a .138 (9/64" maybe) wall black pipe using a SAMW electrode (was trying to lay a bead on it, not cut it).  I have not used the ford yet.  I got it because I have heard of people using it with great success.
Reply:thanks for all the help anf info guys, i've been talking with local welders in my area as well and i think i am going to go either for the bobcat 250 or the trailblazer 302. now i have heard that the bobcat isnt that great for TIG is this true?-->amazing what a 1.3L can do
Reply:Originally Posted by rotaryrocketthanks for all the help anf info guys, i've been talking with local welders in my area as well and i think i am going to go either for the bobcat 250 or the trailblazer 302. now i have heard that the bobcat isnt that great for TIG is this true?