Generator Tales

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Today I spent most of the day catching up on things around the ranch that need welding. It's not much but I threw up a small camera so the folks who've been asking will see that a generator indeed can run everything you need. From 1-7/8", 14ga tubing for horse shaders to 1.25" solid steel sucker rod to 3-1/2", .125 wall thickness steel oil pipe we use for corral framing to the crack I had to fix in our 3/8" solid plate tractor bucket wall that I stop drilled and welded, the 6500 Honda (on loan to me from Ed Screamin' Broccoli" and a BIG THANKS again) never even burped... not even when it was running the Longevity 42i Plasma Cutter.  More than enough power for the Longevity, my 180 Lincoln dialed all the way up and all the power tools we could fit in the back of the Gator.
Reply:Good deal. On a safety note please don't put your body underneath a raised bucket like that without it being supported by a safety support or stand. I'm no safety nazi but that is something that even my father (the kind of person who immediately removes guards and such on equipment) drilled into me back when I first started running equipment.Hobart Stickmate LX235AC/160DCRanger 305GVictor 315 O/A rigHope to acquire in the next couple of years: Hypertherm PM45 and Dynasty 200DX
Reply:Now there's a good recommendation. Thanks.
Reply:jlames - You ever think about stick welding?To me, for that sort of patch work, it seems like with "wire" the logistics of getting generator/feeder/gun close enough to the work would be more hassle than it's worth.Thanks for the picture show!
Reply:Yes. I'm going between 1) a Ranger/Bobcat thing that has the built in generator and just calling it good with that setup and our 180 thanks to Al and 2) a Buzz Box and a Longevity or other MTS like a Miller or a Lincoln with a top-of-the-line generator. But with Joyce's arm and helping out with her business, my Discovery Channel project and the ranch, plus the fact I don't really make decisions fast which has always served me well, there's simply not alot of time. Add to that the fact that I've only been welding less than a year now and you have the reason I'm so grateful that people like you and the others here on this board exist. I'm looking at what seems to be a really great deal on an EB7000 Ed (Brocolli) turned me onto over the next couple of days so that may be an option too with a stick set up but new with warranties play a big role in our decisions. For those of you old enough to remember "The Odd Couple", I make Felix Unger look like a Funny Car driver!!! As I've mentioned, Joyce and I are in our mid-50s and planning for retirement so we're figuring whatever we buy, like our stable of John Deeres should be the best we can buy because we want them to last us the rest of our lives and things we'll hand down to our daughters' families for their families. Anyway, too long of a post but thanks for the idea. It's a good one.
Reply:I would be to worried about the bucket coming down on me to focus on welding. I know its a rare thing but it just takes once. Its a great vid thoe.Have you thought about a miller wildcat. My old neighbor keeps one in his Polaris ranger, and loves it for the light fixes.PROUD   AMERICAN
Reply:I agree. You'd think after 40 years around tractors and horses, I'd know. Long day and, as you can see, I wasn't thinking much. Anyway, we're putting together an all-purpose rig right now for the shop and ranch; one we can back the Gator up to and drag anywhere on the property and fix anything. Thanks to Al "Killdozerer11", it's going on a small, custom trailer that sits central to the shop and we're deciding on the components. It could be a Bobcat or Ranger with a plasma cutter or, as we're leaning right now, an EB7000 with an MTS setup and plasma cutter. The 6500 is a well-appreciated loan from Ed "Screamin' Broccoli" so I could get a few of the fall repairs done that are needed before winter sets in. (Not including the tractor. That was a slight accident on my part!)
Reply:+99 on do NOT get underneath hydraulic equipment like a front bucket UNLESS you have mechanically rigged and supported the object.Just like you do NOT get underneath a vehicle supported by a jack unless and until you put it firmly on jack stands (or some other form of solid mechanical support).The Honda 6500 gen set can run pretty much any power tool (120V) that you could use.  Actually, it's overkill for 120V tools.  But it's need to run the 240V items like the welder or the plasma.Speaking of welders and plasma cutters, check the manual on what sort of generator power is needed to run those type machines.  Example:  a Hypertherm (had the manuals handy for look-up, and Hypertherm makes some nice plasma cutters ) PowerMax30 needs at least a 5.5 kw generator to run at full power and a PM45 needs at least an 8 kw generator to run at full power.  YMMV depending on exactly what machines (generator and plasma cutter or welder) you are using or planning to use.  Second example:  a Lincoln AC225 stick welder (buzz-box) or similar needs at least a a 12 kw generator in order to run, because of the (relatively) large internal transformer and the rather large 'surge' current the machine needs in order to run.  RTFM or ask (email or call) the machine's manufacturer and see what is required in order to run off of a generator.  btw, what did you use for the air source for the plasma?  (don't feel like looking up any specs on that particular make/model of plasma and didn't see an air compressor in your vid).For machine selection (generator and welder and other tools), you have to decide what your actual needs are and what/where you will make trade-offs (size, weight, cost, capabilities, etc).  Although some portable generators are able to run some 'portable' welders, you have to check (or in your case, do some actual test runs    ) to see if the combo you pick is going to work (for you).You can also go the route of an engine-drive welder.  They come in various 'sizes' (and 'colors'    ) and also various capabilities.  Some are AC stick only, some are AC/DC, some are multi-process capable, some have generator capabilities also, etc, etc.  Some are about the size/weight of a small/medium generator (about 200 lbs, give-or-take), and then you can move up to the 'real' engine drive welders, which seem to run up near the 500 lb weight (or higher, for the 'big boy' machines    ).  Those 'real' engine drives often have ~10 kw generator capability as well, so you can run (most) other tools or machine (air compressor and plasma cutter come to mind).Or for cutting, you can go electricity-free and run an oxy-fuel cutting set-up.  Multiple choices of what tools/machines you could choose.  Your call on the trade-offs.But please, don't get underneath things supported hydraulically (jack or tractor implements).  Block it up, crib it up, use jack stands, etc and solidly support the item before you get underneath it.  The best laid schemes ... Gang oft agley ...
Reply:Call me just-as-guilty-for-getting-under-the-loader-bucket for a few seconds at time.My welding kit started off with just oxy-acy & a buzz box on a cast-off cart. The cart now holds oxy-acy, MIG and a TIG/stick welder. Once you decide what is needed out in the field, be prepared to change it!
Reply:Johnathan,the EU6500 and even the EM7000is that i have a line on will not power a Buzz Box.  What is an "MTS set up?"Ed Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:Johnathan that's a no no ..The Safety police !!Doing ranch>>> fence<<<type repair like that is easy with a little FCAW machine probably quicker to use than a stick setup now a days..Dragging around 1/0 or 2/0 cables is a PITA if you don't need to ..But stick will still be king of doing general repair workRunning a plasma cutter and a compressor off a bobcat or red equivalent will not work ...not enough power once the compressor has to run at the same timeso you would need a separate gen to run the compressor or the plasma cutter....  due to start current needs of the compressor...you would risk damaging the plasma cutter by brown out every time the compressor has to start...also not good for the compressor motor either..not to mention the poor gen trying to provide the power neededIf you're going to get an engine drive i would forget about the buzz box unless you want it as a backup machine in your shop running off of shop power as i don't think the gen will supply enough power to run itJhonathan i have been looking at trailer designs that will fit your needs and have found a nice design that can be modified to whatever engine drive you decide on and there are many and i probably have missed some but here is a pic of one design which is a skid on a trailer ..which allows you to remove it with a set of forks on your tractor ...It is a little over the top with those reels but other things can be done that are cheaper so don't look at me like that...I like it because it is versatile and elegant and cheap to build with a few changes Attachment 497021Attachment 497031Attachment 497041Last edited by killdozerd11; 09-19-2013 at 03:06 PM.Backed my CATMA over your CARMA oops clusmy me  What would SATAN do ?? Miller Trailblazer 302 AirPakMiller Digital Elite  Optrel Welding HatArcair K4000Suitcase 12RC / 12 VSHypertherm PM-45Rage 3 sawRusty old Truck
Reply:Hi all. As to the MTS, Ed, it's a MIG, TIG Stick machine that I don't know much about yet so I'm sticking with what I know; my Lincoln 180 which I know the generator doesn't even notice is there. It's like  a gnat to the Honda. As for the Plasma cutter, as I said, it worked great too even though, on reflection, it shouldn't have because the math doesn't work out. (220vX40a=8800w and the genny's only a 6500/5500 machine). But it worked great although I did have the Plasma dialed down to 30a where I started and saw no need to increase it because it was cutting the pipe so well. As to the compressor, I used a small, 6gal, pancake one and put it on its own, small, 1000-watt generator which left all the power of the Honda to the plasma and, as I said, it worked perfectly. You know, in doing this; in putting a "package" together that I can haul around with me, I'm reminded of the old adage, "It's hard to remember that your original intent was to just to drain the swamp when you're up to your *** in alligators." So many options, so many choices, so may needs. Like the pictures of that system, Al. It looks awesome but I simply refuse to drive around hauling anything that looks like it costs more than my house! Just kidding. It's probably not THAT expensive but it's way more than my needs. And it's prettier than our Gator too; something Joyce just will NOT stand for. She LOVES her Gator and make no mistake; it is HER Gator!!!! Sort of reminds me of the guy who's tooling down the road with a $70k horse trailer while driving a $700 truck. As to the stick idea, it's probably a good one but I know nothing of buzz boxes except that they take ALOT of energy and are probably overkill for our needs here. I actually gave a 110v, Lincoln to "Miller Killer" when he and his daughter were here for Weld-o-Rama1 because he liked it and collects them. I think I tried to use it once! I like MIG. I know it's probably not the best choice for, as you say, the patch-work we do in the field on fencing and corrals which are sometimes out in the middle of nowhere where no one will see them, but at this age and at this time, fence-mending isn't work; it's recreation and God says the time it takes me to ride my horse out to the fencing, find it's broken, ride back to the barn, drive the Gator out to the fence, fix it and drive back to my horse, "shall not be deducted from my time here on earth"!!! I guess that's why I'm taking so much time deciding exactly what I want the portable system behind the Gator to be and why I appreciate all of your individual and collective recommendations and comments.So that's it after a day of work. I appreciate more than you can know your concerns and your warnings, your recommendations and observations and I look forward to logging back on this evening to learn more from you all.
Reply:My vote is for an engine drive welder that has CV capability for a wire feeder hookup. The thing I like about my Ranger is it is so versatile. I can stick, hook up a wire feeder suitcase for a powerful MIG/FCAW setup, or do DC Tig on it. I can also if I really want to hook up a spoolgun set up and have aluminum capability. Expensive but worth it to me, IMHO. One thing to note is that at this time I do not have a fixed shop so portability is the name of the game for me. I'd love to have a shop with a big 240v MIG, a big Miller 330A/BP, a big plasma cutter and air compressor, and a huge welding table with a giant vise and an anvil. Unfortunately I do not so having a power source that will do a lot plus power tools in the field is very useful to me.Last edited by JD955SC; 09-19-2013 at 10:53 PM.Hobart Stickmate LX235AC/160DCRanger 305GVictor 315 O/A rigHope to acquire in the next couple of years: Hypertherm PM45 and Dynasty 200DX
Reply:LOVE THE PICS!I am now completely jealous!Gas, stick and work lights on a highway-capable trailer?Fantastic.Be wary of The Numbers: Figures don't lie,. but liars can figure.Welders:2008 Lincoln 140 GMAW&FCAW2012 HF 165 'toy' GTAW&SMAW1970's Cobbled together O/A
Reply:Like you  I am in my mid 50s  and have a ranch that i am rehabilitating  or building up .  I just got it and nothing  has been put into it for 30 or so years .  It was the retirement income for my grandmother , then mother .  Since i am by necessity a tinkerer ( read poor ) I swapped into an old miller legend  and so far have been real pleased with it . My experience is that  while you can use a genset and shop welder to do about anything  for a little while , long term its not near as robust a system as even an older engine driven welder ( don't ask lol ) . Now i am not a welder , just a farm kid that came back to the place after years of doing other things but i know farming and ranching fairly well , and i deal with/fix enough  farmerfixed  stuff on the place  that i really don't want to have to deal with more complex issues on my tools than necessary. The engine drive welder is robust , a single unit to secure in the polaris/pickup/trailer  or whatever  that i don't have to mess with more than one set of connections on .  Its big enough to run my air compressor  when needed  but i use oxy/propane for cutting . I would like to have a nice new bobcat or ranger  but for now and the 500 bucks i spent the little legend is fine . I just really think that as time goes on , the less units you are loading up and hauling around to fix things the better off you will be . Engine drives are built to take a certain amount of abuse and still weld , I don't  think the shop welders are  and am kinda skeptical that most gensets are as well built  . Its sure your place and different needs from mine so only you can say whats going to work for you  but I will note that there is no question that the engine drive welder will work for you and likely last the rest of your life with care ,  can you say the same for the genset approach ?
Reply:It's good to have another rancher like me out there following along as I post and talk about what I'm doing. I saddled-up about  about 4:30 this morning to head out to the back property to enjoy the sunrise, look around for the cougar that we inadvertently fed again the other day with a couple of our chickens, and check the back cattle loading pen and when I got back in, I started loading up the Gator with Ed's Honda genset, the welder, tools and such and I was thinking the same thing. Not to the extent that Al's friend's welder is set up with the lights and all, but a Ranger or Bobcat is looking more and more like the way to go. I'm not using the plasma cutter in the field so much. I only needed it a couple weeks ago because the PortaBand was too big to fit in between the horizontals I needed to cut so normally a portable bandsaw will do just fine. And tossing the lines in for a mig and a stick setup wold be easy. I don't know... What I do know is, when you have the generator in the back of a Gator, keep the exhaust pointed away from the bed liner. They melt really quickly. Now I just have to find a way to tell Joyce I destroyed her bed liner!!! Oh well; it looks like more profit margin for Sam Allen and his John Deere corporation. I wonder how much this is gonna cost me?!?!
Reply:If the box is actual metal yank that plastic out and have it sprayed with a real bedliner. If the box is plastic yank it off and fab up a flat bed out of metal with droppable or removable sides.Hobart Stickmate LX235AC/160DCRanger 305GVictor 315 O/A rigHope to acquire in the next couple of years: Hypertherm PM45 and Dynasty 200DX
Reply:Actually, I just ordered a new liner from Greenfarmparts, our goto on-line JD parts company 5 minutes ago for $256. I like the plastic because it absorbs all the impact from tossing tools and implements into it all day long. The spray-in bedliners adhere right to the metal so the box winds up getting dented. Almost everyone out here has Gators or Kubotas and the one guy who actually has a franchise for spray liners did his Gator and wound up replacing his box after he tossed, ironically, a generator into the back and it dented the box wall. You're right though. We have a spray-in liner on our truck and it's great.
Reply:Should just leave the hole in the liner, it adds character Airco Ac/Dc 300 HeliwelderMillerMatic 200 (stolen)Miller Maxstar 150STLMiller AEAD200LE (welding and generating power) Hobart MIG
Reply:I just cannot stand plastic bedliners but that's me  The ones in our trucks at work are a pain in the rear since if you leave the tailgate down for anything oversize that item tends to slideout and the grooves make it a pain to clean the bed out...We had the standard painted metal box in our gator at work at my old job and it held up very well to all the abuse government employees could dish out. That was one fun set of wheels, too.Hobart Stickmate LX235AC/160DCRanger 305GVictor 315 O/A rigHope to acquire in the next couple of years: Hypertherm PM45 and Dynasty 200DX
Reply:Yeah... That's what wives call it; "Character"!
Reply:Originally Posted by jlamesYeah... That's what wives call it; "Character"!
Reply:Joyce saw it this morning. OK, I told her about it last night but she saw it this morning. Oddly, she said nothing... until later when she  called me on my cell later and asked which of our two dog houses she'd like my mail forwarded to!
Reply:That's rough man! LolBut I'm sure she'll forgive you when the new one is put inDave J.Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:Originally Posted by FarmDadstrange ... Thats not quite the word my wife calls it when i mess up her stuff  LOL .This afternoon when I asked to borrow her Gator!!! That's our friend, Dennis; an attorney. I don't know which is scarrier!