New life to an older war horse

[Frank Surber]

Not all that old but the serial number on it means it is near 30 years.
One of my customers has me refurbish a few welder generators from time to time.
Most have been smaller machines like the Miller Wildcat a couple of Miller Bobcats and a legend or 2
The last time I visited his place of business I hauled off a 2250 lb hulk of iron that once was a Miller 400 airpac.
I told him I was stealing it and if I could get it going he could have it back someday




I stripped off enough of the sheet metal to work on it to my surprise after I replaced the 10 year old fuel and connected a battery it started right up
But no power generation of any kind the air compressor pumped air but the regulator was gummed up so the pressure climbed to around 150 then the relief valve opened.
I cleaned the slip rings then started it up again this time it had 120v ac but no weld current to speak of it wouldn't even burn a 1/8" 7018 rod at first. then I racked the rotary switches back &b forth several times and tried it again this time it would burn any rod I could get in the holder even smoked a 1/2" gouge carbon
the 12KW 3 ph option had no problem starting up a 7 1/2 Hp motor os now it was time to see about making it look a little better








The engine covers were both missing
I had to have a punch & die special ground for tight clearance because of the close placement of the Obround holes



the door I had made was formed a little wrong so I had to reform it

Flattened and ready for re forming

 

[Frank Surber]

Clamped in my unfinished folding break
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First fold complete
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Formed primed & painted
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it has a couple of wrong lables and they are not in the correct place for this serial number
but all in all it looks just fine according to my customer
in fact he often accuses me of replacing his machines with others that I find
View attachment 385450

 

[Frank Surber]

Clamped in my unfinished folding break

First fold complete

Formed primed & painted







it has a couple of wrong lables and they are not in the correct place for this serial number
but all in all it looks just fine according to my customer
in fact he often accuses me of replacing his machines with others that I find

 

[Mark @ Everlast]

You just quadrupled that machine's value. Good work and good patience.

 

[Big Barn]

Really nice job, Frank!

Terry

 

[dclynch]

Looks Awesome wish I had that talent and patience

 

[Happy Gilmore]

Wow, great work! :thumbsup:

 

[Frank Surber]

Here is one of the toy machines I did for him. Actually it was the first machine I worked on for him
OK TOY is not fair but to me if it is not big enough to burn a 7/32" 7024 laid into a 2" plate with a full pin "V" grove it is strictly a hobby machine

pretty bad shape

every single piece of sheet metal and all frame parts were bent up





ironing out the bumps

no it is not impossible to make this look good again



Sheet metal now straightened ready for sanding & body filler where needed

control panel straightened and painted

 

[Frank Surber]

Here is what it looked like when I finished after final sanding and painting
The bad thing was the little wildcat only had 24 hrs on the clock when the truck it was mounted on was rolled over

in the end I did replace a few parts like the plastic Bezel on the control end most of the plastic parts were replaced and 2 of the side covers because I was never quite satisfied with how they were turning out I don't like to use bondo if I can get out of it

 

[Frank Surber]

this is another this time a Bobact