Welding with an alternator??

montanaman · Dec 2, 2006

Was posting to another question and it brought up one of my own. There are a few places that sell alternators with control boxes so they can be used for stick welding. Just wondered if anyone had the know how to build something like this as the ones I've seen are pretty expensive.

I had looked at the production units a few years back and instead of good info, these places were spending a lot of effort bashing each others products so I skipped the whole idea.

So does anyone know how to make one? I know it's pretty cheap to hot rod a 10SI to gett some good amperage out of one!!

Ken

SPIKER · Dec 2, 2006

Most of the time on alternators it is the DIODE pack that are the weak link. They are designed for short periods of higher amperage (after starting say) and longer periods of smaller draw, (radio/ignition ect.) in real world alternators don't supply enough power to run ALL of the accesories at once without keeping them at a high RPM with good cooling. turn on all the lights heat ect then you end up using all the alt juice and some battery juice at times especially when ideling low/slow...

addapting one or sevearal alternators to make a welder can be done, and kits are available like you said from many places. generally replacing the weak links (diodes) with larger higher amp units are part of it. some also want higher load windings... or making a welder that uses several alternators is even better.

hardest part is controlling the amperage fine enough to actually WELD controllably. that is harder... (i'll leave my thoughts out of that one due to I'm not sure what is best or easiest way or even which way works)

anyhow keep us posted if you come up with good parts ideas and or places to get them...

MarkStewart · Dec 2, 2006

Check out this link. Might be of interest. Machine Builders Network

Volfandt · Dec 2, 2006

I've had pretty good performance out of a 75amp Delco running off of my old 865 Wheel Horse. I elected to keep the voltage high so I could power some tools with it but the alternator can be rewired into a delta config to produce much higher amperage.
http://www.tractorbynet.com/forums/...re-welder-well-sort-3.html?highlight=volfandt

Volfandt

RonJ · Dec 3, 2006

Try this link:
Jon's Place/Jeep Page
There should be a link at the bottom of this page that covers the entire project.

montanaman · Dec 4, 2006

Thanks very much folks! Lots of good info and links there. I've been on Machine Builders Network and I have to say it is an awesome site. One of those sites that makes you wish you were going to live for ever so you could have more time to build!! I guess that would still leave the problem of where to hide everything from the wife!!

I have done so much research on future projects but I'm getting smarter about knowing the ones I'll never have time or money to complete!

Ken