My Miller Welder Project

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I bought this Miller Thunderbolt 225V welder with the understanding that it would barley spark when trying to strike an arc. Well as soon as I saw the power cord I closed the deal hoping that this is the only thing wrong with the welder. ( like I need another one the wife says, as I have 6 so far). Any way here's the pictures. First group are of the welder on cart in my garage for the first time. Attached ImagesMiller Thunderbolt 225Millermatic 130 XPLincoln HD 100 Forney C-5bt Arc welderPlasma Cutter Gianteach Cut40ACent Machinery Bandsaw Cent Machinery 16Speed Drill PressChicago Electric 130amp tig/90 ArcHobart 190 Mig spoolgun ready
Reply:This second group are of the welder off the cart and beginning to take apart for a closer look. Attached ImagesMiller Thunderbolt 225Millermatic 130 XPLincoln HD 100 Forney C-5bt Arc welderPlasma Cutter Gianteach Cut40ACent Machinery Bandsaw Cent Machinery 16Speed Drill PressChicago Electric 130amp tig/90 ArcHobart 190 Mig spoolgun ready
Reply:This third group is the internals which have not been cleaned in a while looks like to me. As you can see the on off switch and the shunt look in need of some attention. Well let the fun begin. Attached ImagesMiller Thunderbolt 225Millermatic 130 XPLincoln HD 100 Forney C-5bt Arc welderPlasma Cutter Gianteach Cut40ACent Machinery Bandsaw Cent Machinery 16Speed Drill PressChicago Electric 130amp tig/90 ArcHobart 190 Mig spoolgun ready
Reply:Sorry about that here is the power switch and some more fun. Attached ImagesMiller Thunderbolt 225Millermatic 130 XPLincoln HD 100 Forney C-5bt Arc welderPlasma Cutter Gianteach Cut40ACent Machinery Bandsaw Cent Machinery 16Speed Drill PressChicago Electric 130amp tig/90 ArcHobart 190 Mig spoolgun ready
Reply:All most done now.This took two days so far. Attached ImagesMiller Thunderbolt 225Millermatic 130 XPLincoln HD 100 Forney C-5bt Arc welderPlasma Cutter Gianteach Cut40ACent Machinery Bandsaw Cent Machinery 16Speed Drill PressChicago Electric 130amp tig/90 ArcHobart 190 Mig spoolgun ready
Reply:Sorry about the long post, but some one may need to see the inside of a Miller 225V, and It was a learning project for me.Miller Thunderbolt 225Millermatic 130 XPLincoln HD 100 Forney C-5bt Arc welderPlasma Cutter Gianteach Cut40ACent Machinery Bandsaw Cent Machinery 16Speed Drill PressChicago Electric 130amp tig/90 ArcHobart 190 Mig spoolgun ready
Reply:That certainly turned out pretty goodI like the fine tune on the amps.  Lack of fine tune is a real drawback with my little Lincoln.Now you gotta make everybody sick by tellin' what ya paid"Any day above ground is a good day"http://www.farmersamm.com/
Reply:Looks new again, good job!
Reply:was the plug the only thing wrong with it?
Reply:You did a great job cleaning it up and painting it. How its working?Co-Own CNC shop:Miller :1251 plasma cutter, MaxStar 700 TIG/Stick, & XMT 456 Multiprocess Welder.&  2 Hypertherm HPR260's Plasma CutterSorry I had a bad stroke but now I am back.
Reply:Neat.  So how does it work now that it's all cleaned and spiffed up?  The best laid schemes ... Gang oft agley ...
Reply:You did a very nice job!! Hows it work?
Reply:Is the paint Miller blue? looks goodAmerican by birth Southern by the Grace of God
Reply:Farmersamm Your pretty sharp, I paid 30.00 for the welder. And the fine amp tuning is one thing I liked about the welder myself. I figure if it doesn't work, the leads fit the Forney and are worth that.Thanks BadtexasZ28 it was fun for me.Hideandseek I don't know if the plug was all that is a wrong with the machine (I strongly suspect it is) but have to wait till Friday to get a new plug for it and see.Specter, Moonrise, Weldershane thanks for the complements, but gota wait till Friday to get the plug and try a bead or three.74fencer The paint is Royal Blue closest to Miller blue I had on hand (but it is real close to Miller blue).Thanks for looking everyone, and I'll update it on Friday when I get to try it out (I hope it works).Miller Thunderbolt 225Millermatic 130 XPLincoln HD 100 Forney C-5bt Arc welderPlasma Cutter Gianteach Cut40ACent Machinery Bandsaw Cent Machinery 16Speed Drill PressChicago Electric 130amp tig/90 ArcHobart 190 Mig spoolgun ready
Reply:I re-worked my Miller Thunderbolt last year. It is the orginal welder I used in metal shop in high school. My dad went to the school auction and got it for me. They are great machines.  One thing to know after doing the cleanup is that you might need to tighten the four screws around the coil. You will know the second you strike up the arc.It will have a loud buzz and vibration.  If you get it too tight the plastic handle will break. I learned that from experience. I also had to get another power switch from Miller. The contacts were shot in the old one. The new one really make click sound.  You can just about get any part for these except the white panel.  I will post a picture later .Nice job looks real nice.My Gear is:Two Miller Thunderbolt 225Millermatic 211Miller Spectrum 875 PlasmaMiller Spot WelderLincoln SA-200
Reply:That Forney in the background looks like the same welder I learned on, my dad replaced it with a Thunderbolt AC/DC back in the early 90's(WOW what an upgrade, like night and day)...Nice work on the restoration, makes me want to go clean up the ole AEAD 200LE( but the snow and freezing rain have got me discouraged at the moment,  I wont say what I paid for it until I can post some restoration pics)...JimLincoln Power Mig 255Hobart Stickmate AC/DCMiller AEAD 200LECutmaster 81
Reply:All right JiminIA restore that machine and tell us a story Miller Thunderbolt 225Millermatic 130 XPLincoln HD 100 Forney C-5bt Arc welderPlasma Cutter Gianteach Cut40ACent Machinery Bandsaw Cent Machinery 16Speed Drill PressChicago Electric 130amp tig/90 ArcHobart 190 Mig spoolgun ready
Reply:Holy cow! that thing looks killer!
Reply:i like how it came out. i am thinking of doing the same thing to my thunderbolt after looking at how nice it is.4 1/2 inch angle grindermiller thunder bolt
Reply:Well the Good news for me is that, the plug for the power cord is all that was wrong with the welder! So I bought two boxes of Lincoln 6013 rods one is 3/32" and the other is 1/8"All the welds you are about to see are with the 3/32" rods. First group of pics are from first pic to last in the order of the welds ( first pic first weld with stick second pic is the second weld and so on) there were only four welds total. And the first two I didnt think to get the pic with the flux on the weld but I did on the third and forth welds. Mind you the only stick experience I have is with a 70amp 110vlt C.H.Oh before I forget the setting on the welder were 112amps and a 3/32 rod 6013 Attached ImagesMiller Thunderbolt 225Millermatic 130 XPLincoln HD 100 Forney C-5bt Arc welderPlasma Cutter Gianteach Cut40ACent Machinery Bandsaw Cent Machinery 16Speed Drill PressChicago Electric 130amp tig/90 ArcHobart 190 Mig spoolgun ready
Reply:In the fifth pic you can see the flux curling up and trying to come off by it's self... Next two pics are the third weld, the two after those are of the fourth weld. The pit/porosity in the third and forth welds are where I started another rod. In the third weld I thought to slow changing the rod. In the forth pic I thought, all ways clean up the weld before starting another rod. I knew that you guys/gals stress that all the time. (Thanks) Attached ImagesMiller Thunderbolt 225Millermatic 130 XPLincoln HD 100 Forney C-5bt Arc welderPlasma Cutter Gianteach Cut40ACent Machinery Bandsaw Cent Machinery 16Speed Drill PressChicago Electric 130amp tig/90 ArcHobart 190 Mig spoolgun ready
Reply:And here is the machine on it's cart after cleaning the cart up and putting it back on. With the leads having a proper way to store them ( hanging on the back of the cart ) not laying on top of the welder.Tell me what you think about the welds, and as all ways thanks for all the help. Attached ImagesMiller Thunderbolt 225Millermatic 130 XPLincoln HD 100 Forney C-5bt Arc welderPlasma Cutter Gianteach Cut40ACent Machinery Bandsaw Cent Machinery 16Speed Drill PressChicago Electric 130amp tig/90 ArcHobart 190 Mig spoolgun ready
Reply:Nice job you did there sir. Those things were built like battleships. The sad part about all of this is your going to have to do it all over again in 40 years from now Good thread and great work. Happy Holidays. Paul Miller 302 Trailblazer/Custom TrailerMillermatic 350P/Spool gunMillermatic 252Miller Spectrum 875Miller Dynasty200DxHypertherm Powermax 85Tracker CNC 4X8 Pro Table (Down Draft)Visit us @ www.specialtyrepairscustommods.com
Reply:Originally Posted by STwelderAll right JiminIA restore that machine and tell us a story
Reply:Jim put that tarp back on the welder please! I'm looking forward to seeing your restoration on the Big40.I know I'll learn a thing or two about the gas driven welders from the thread.Miller Thunderbolt 225Millermatic 130 XPLincoln HD 100 Forney C-5bt Arc welderPlasma Cutter Gianteach Cut40ACent Machinery Bandsaw Cent Machinery 16Speed Drill PressChicago Electric 130amp tig/90 ArcHobart 190 Mig spoolgun ready4Shorts I'll be faster about the refirb in 40 years even though I'll still be quite slower by then I'm sure. And the welder was a pleasure to weld with, seems like with more power the welding is easier. Or the finesse is a whole lot easier to adjust to.Miller Thunderbolt 225Millermatic 130 XPLincoln HD 100 Forney C-5bt Arc welderPlasma Cutter Gianteach Cut40ACent Machinery Bandsaw Cent Machinery 16Speed Drill PressChicago Electric 130amp tig/90 ArcHobart 190 Mig spoolgun ready
Reply:Awesome restoration ST and nice welds.  Glad it all worked out the way it did.  I've been keeping an eye out for a restoration project myself and running across something like you and JiminIA did would be great.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:I think you got it dialed in towards the end.There's nothing slicker than seeing the slag on 6013 curl up and self peel.  You know, without looking, that there's a nice looking weld underneath.  Tap it with the chipping hammer, and the whole length of slag comes off.  No beating it to death."Any day above ground is a good day"http://www.farmersamm.com/
Reply:Duane thanks for the comments and words of encouragement! I saw this welder on Craigslist and though  it's been posted for like 3 hrs when I saw it and for 30.00 if it has leads (there worth that) its gone.....But I e-mailed anyway... nothing for about 7 days. Kept seeing it and thinking I was right it's gone. Then saw it and noticed there was a phone number that wasn't there before..... ( thought call right away ) so I did and the guy said your the first one to call you have first dibs, one question I said, does it have the leads with it? He said the clampy things one holds the rod yes. I said How soon he said tomorrow I said I'll be there.I felt like the welder was meant to be mine, or I just jot lucky something that doesn't happen that often to me.      So keep your ears open and checking and you will get yours Miller Thunderbolt 225Millermatic 130 XPLincoln HD 100 Forney C-5bt Arc welderPlasma Cutter Gianteach Cut40ACent Machinery Bandsaw Cent Machinery 16Speed Drill PressChicago Electric 130amp tig/90 ArcHobart 190 Mig spoolgun ready
Reply:Farmersamm you are absolutely right about the 6013 slag self peeling. I jumped up and shouted yeah did a little strut and said who's the man.... I am hahaha.did the same when I hit the slag with the peck hammer and all the slag fell of in just a couple pieces.  Felt good. Thanks for the comment!Miller Thunderbolt 225Millermatic 130 XPLincoln HD 100 Forney C-5bt Arc welderPlasma Cutter Gianteach Cut40ACent Machinery Bandsaw Cent Machinery 16Speed Drill PressChicago Electric 130amp tig/90 ArcHobart 190 Mig spoolgun ready
Reply:Originally Posted by duaneb55Awesome restoration ST and nice welds.  Glad it all worked out the way it did.  I've been keeping an eye out for a restoration project myself and running across something like you and JiminIA did would be great.
Reply:STwelder:Great restoration job. It sure is great to see something like this brought back to the life it deserves.Question:What did you use to clean it up? You got the copper looking like new. Did you replace the fan?Keep up the good work.Sign on East Texas payphone: Calls to God 40 cents......it's a local call...
Reply:Stampeder To clean it up I used Scotch Brite green pads, no water, these also do the sanding to get it ready for painting. The copper I used WD40 on a shop rag and light rubbing so as not to remove the varnish. As for the fan just cleaned and blew it out with air 70psi. It just takes time and patients, but I think it was worth ever minute of it. Duaneb55 Did you see what JiminIA said? There's an opportunity knocking.Miller Thunderbolt 225Millermatic 130 XPLincoln HD 100 Forney C-5bt Arc welderPlasma Cutter Gianteach Cut40ACent Machinery Bandsaw Cent Machinery 16Speed Drill PressChicago Electric 130amp tig/90 ArcHobart 190 Mig spoolgun ready
Reply:STwelder,Great job! Thanks for sharing the pictures with us. I bought almost the same welder in December, but I think mine is a little older. It was made in 1983. I stripped it down, cleaned it, and painted it. I used Rustoleum Safety Blue and it is a close match to my MM140AS. I only brushed the dirt off the coils because I did not want to chance damaging them. I will try the WD40. It is easy to weld with, but my stick welding needs a LOT of practice before I post any pictures.Here is my question (maybe someone else can help, too). When I plug in my leads, there is about a 3/8" gap between the end of the plastic handle on the lead and the plastic ring on the connector, leaving the copper exposed. I don't think that is normal, is it? But the lead is so tightly connected, that I cannot easily pull it out. Maybe you can give me some tips on how tightly it should fit and how to make good connections without being too tight.Burt _____________________Miller Syncrowave 250Millermatic 211Miller 375 Plasma Cutter Hobart Handler 12010FtDrillBit.com
Reply:wb4rt That is the same way my leads do on the Miller and the Forney so I suppose it's normal. Nothing for you to worry about there.Post some pics of the machine and the welds after you practice some more.Miller Thunderbolt 225Millermatic 130 XPLincoln HD 100 Forney C-5bt Arc welderPlasma Cutter Gianteach Cut40ACent Machinery Bandsaw Cent Machinery 16Speed Drill PressChicago Electric 130amp tig/90 ArcHobart 190 Mig spoolgun ready