mitchash
Gold Member
Has anyone done the DC conversion on a older AC stick welder? I’ve seen a few videos on it. Wondered if I should try it on my Miller Thunderbolt?
AC to DC stick welder conversion
- Thread starter mitchash
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ewoz
Bronze Member
I did it many years ago to my Craftsman. I bought 4 stud mount diodes and mounted then on two roughly 2.5' x 2.5' sheets of copper. I noticed a difference. I haven't seen any of the videos showing how they are doing it these days.
ewoz
Bronze Member
That would be a simpler way to go. If you can get one for $20 it would probably even end up being cheaper.
ewoz
Bronze Member
I was able to switch between AC and DC with my setup. My rectifier assembly had plugs and jacks so that you could either plug the rectifiers into the welder or plug your welding cables into the welder. I would be concerned with junction temperatures of the rectifier assembly you showed, but if it is working it's great!
grsthegreat
Super Star Member
guess i lucked out, as my Miller thunderbolt is already a ac/dc machine. i actually thought all the thunderbolt line was.
kneedeep
Veteran Member
Mine is AC/DC
Thunderbolt
Thunderbolt
Fuddy1952
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Yes it can be done, I'd be sure heat sink for diodes is sufficient, maybe put computer fan on it (heat destroys diodes).
Maybe check surplus electronic suppliers.
WranglerX
Super Member
Should not be to difficult.... See graphic in post #4...
There is also a 400 amp version...
Bridge Rectifier 300A High Power Single Phase Diode Bridge Rectifier 4 Terminal Full Wave Diode Module 1600V Single Phase Bridge Rectifier: Amazon.com: Industrial & Scientific
Bridge Rectifier 300A High Power Single Phase Diode Bridge Rectifier 4 Terminal Full Wave Diode Module 1600V Single Phase Bridge Rectifier: Amazon.com: Industrial & Scientific
www.amazon.com
There is also a 400 amp version...
1pc Singe Phase Rectifier Module Rectifier Diode Bridge 4 Terminals MDQ 400A/1600V: Amazon.com: Industrial & Scientific
1pc Singe Phase Rectifier Module Rectifier Diode Bridge 4 Terminals MDQ 400A/1600V: Amazon.com: Industrial & Scientific
www.amazon.com
Sberry
Platinum Member
That would have been cool years ago. Its kind of cool now and makes it a whole level better machine. If it was a hobby and didnt care it would be ok but if I had to spend much to get this done would be hard pressed to get away from a new inverter. The buzzers are reliable and have seen some used hard, I been down the trail a while and have a hard time remembering any really burned up.
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Gordon Gould
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That's what I thought several years ago. I finally figured out that to get better and more consistent I needed finer currant control than on my Tombstone. I bought a EverLast PowerArc 200ST. Inverter 200 Amp DC welder. For me changing to DC made a huge difference that I had not anticipated. So changing to DC does make a difference.
gg
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fried1765
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My 30+ year old thunderbolt is AC/DC.
I too thought all Miller thunderbolts were AC/DC.
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Big Barn
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I did the same on the farm for 45 years before I had DC. I used 6011 and 6013. Never even tried 7018 until lately.
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Sberry
Platinum Member
Lis. I kind of think its a shame someone didnt grab you by the short hairs to the welding store way earlier. I ran across a maintenance guy recently got put out of a job by some kid with whiz tig skills. Shame is he got a pipefitter bro in law, ran him thru my booth and they guy has the talent and would have been a natural with a stinger. A lot of wasted career due to lack of welding skills.
Something that sticks out like the sore thumb is good cut weld skills and anyone going in to mechanical, engineering, the trades doesnt stop long enough to learn a little weld is hampering themselves and a welder can simply do jobs the non cant and follow that up the chain to include some more sophisticated work and its a huge difference between men. Especially trade guys. I know a couple carpenters aint pounded a nail on a job in a long time. Shield Arc being one of them.
Something that sticks out like the sore thumb is good cut weld skills and anyone going in to mechanical, engineering, the trades doesnt stop long enough to learn a little weld is hampering themselves and a welder can simply do jobs the non cant and follow that up the chain to include some more sophisticated work and its a huge difference between men. Especially trade guys. I know a couple carpenters aint pounded a nail on a job in a long time. Shield Arc being one of them.
ROUSTABOUT
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They make 7018 AC rods.I did the same on the farm for 45 years before I had DC. I used 6011 and 6013. Never even tried 7018 until lately.
Sberry
Platinum Member
They do and I used them a lot but they are a little loose on vertical and have to use a little weave to get them to hang in there and a bit tougher to make a flat bead. It takes a bit more skill than DC. The first pic is AC, second is DC and they could be improved some with a little practice. I am far from a daily driver anymore and its real work to hang with it till I weld a little for a week or so.
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