Lincoln Handy Core 100 modifications???

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Hey Guys and Gals,I just found this site and I am so glad I did.  I have been welding for about 4 years (hobby welding).  I have what I believe is a first generation Handy Core 100.  It is the one with only 1 high low switch and no cooling fan.  I was thinking about replacing the switch with a reostat or a multi position switch.  Right now I only have 35 or 80 amp options.  I would also like to add a cooling fan.  Is there anyone out there that has done this sort of thing or has a picture of a higher model (AKA more expensive) liicoln welder that has a multi position switch and a fan already installed.Thanks in advance and Great Site
Reply:Hello Jakxxx,I think I know the machine you’re talking about, but I can’t find any information on it.  I guess I’ll just have to comment based on my memory,I don’t think replacing the hi-low switch with a multi-tapped switch or a rheostat will work.  The power through that switch is probably way too high for any rheostat I’m aware of, and a multi-tap switch will only work if you have taps in the transformer winding to connect to.  There is also the possibility that the wire drive circuit may not be compatible with the modifications.If my memory is correct, that machine is a very low-end import and has very little in common with the US made small wire feed machines.  If I recall correctly, it doesn’t even have an easily serviceable gun and cable.  I don’t think you can even replace the cable liner.  It was only sold for a short time, so if something should break; getting parts may be difficult, expensive, or impossible.In my opinion, you would probably be better off selling it and putting the money towards a higher end machine.  Cheers,BobC
Reply:thanks Bobc,I bought the welder from Canadian Tire and I did find it on the Lincoln site before I purchased it.  The thing is completely servicable.  I took the side cover off and looked at the high-low switch.  It has rating markings of 125v and 15a.  This is what made me think it would be possible to install some sort of variable switch.  You said in your post that the transformer would have to have taps to install a multi switch.  Is that the way they are all made? ie with several leads coming from different sections of the transformer?Thanks again
Reply:My memory may not be perfect, or possibly a special model was made for Canadian Tire.  Do you have a code number?Every machine I have seen, (where I work, I see mostly Lincoln products)  has either a taped transformer or electronic voltage control that uses SCRs to control the input to the transformer.The current Handy Core uses a double switch to adjust the primary winding.  This gives 4 voltages to choose from.  The Weld-Pak 100 type machine uses a 4 or 5 position tap switch on the secondary side of the transformer.  The "Plus" machines, SP-135 Plus, etc.  use electronic control.Each tap has a corresponding lead coming from the transformer.Last edited by BobC; 05-18-2006 at 02:04 PM.