Ian
Notorious member
Now down to the real project, after proving the concept with the on-board unit in my pickup.
Most of my welding needs are covered by 6010, 6011, and 7018 rods of the 1/8" flavor, so DC amp requirements are under 150 and a lot closer to 90-120 for the digging rods. The concept build showed that 25 volts is a good minimum for arc length, and 150 amps is my predetermined maximum need, which equates to 3750 Watts of power. The alternator system I'm using is about 57% efficient at converting mechanical to electrical energy, so means I need a 6600 Watt powerplant, or just under nine horsepower not accounting for other losses.
For starters I sourced a free but locked-up 11 HP B&S Vanguard engine and got it running after honing the cylinder, grinding the valves, replacing the carburetor, and repairing a bunch of other odds and ends. Next challenge was the drive pulley, since I insist on the efficient and torque-capable multi-V designs and none exist for a 1" keyed shaft. I bought a new Chevrolet crankshaft pulley and a 1" keyed hub from Tractor Supply, then turned the hub back on the lathe to make a pilot and clamping face for the pulley, then drilled and tapped three bolt holes to marry the two.
That's as far as I got so far, now to fab an alternator mounting bracket, adjuster, frame for the engine, convert another alternator, and rig up a control panel and all the diode blocks.
The engine doesn't have an electric starter but does have an alternator and it does work. The regulator/diode module was bad so I grabbed a new one off A-zon for $8. This will keep the system battery charged and hopefully keep the battery voltage a little above static level when powering the weldernator field. If I get the pulley sizes and RPM correct, I should be able to run brushed power tools on this system without any difficulty.
The control panel will have gauges for welding output voltage, field voltage, battery/charging system voltage, a rheostat for controlling field voltage, a "weld" switch that powers the field, and remote kill switch for the engine. I'll also put an electrical outlet on it for running power tools.
On the way are rectifiers, a big heat sink, and some other small parts.
Here's a photo of the engine and pulley with the weldernator mocked up in place and wearing the wrong pulley. I'll put a 2.5" pulley on there when mounted for real and about a 31" 6-groove belt.
Most of my welding needs are covered by 6010, 6011, and 7018 rods of the 1/8" flavor, so DC amp requirements are under 150 and a lot closer to 90-120 for the digging rods. The concept build showed that 25 volts is a good minimum for arc length, and 150 amps is my predetermined maximum need, which equates to 3750 Watts of power. The alternator system I'm using is about 57% efficient at converting mechanical to electrical energy, so means I need a 6600 Watt powerplant, or just under nine horsepower not accounting for other losses.
For starters I sourced a free but locked-up 11 HP B&S Vanguard engine and got it running after honing the cylinder, grinding the valves, replacing the carburetor, and repairing a bunch of other odds and ends. Next challenge was the drive pulley, since I insist on the efficient and torque-capable multi-V designs and none exist for a 1" keyed shaft. I bought a new Chevrolet crankshaft pulley and a 1" keyed hub from Tractor Supply, then turned the hub back on the lathe to make a pilot and clamping face for the pulley, then drilled and tapped three bolt holes to marry the two.
That's as far as I got so far, now to fab an alternator mounting bracket, adjuster, frame for the engine, convert another alternator, and rig up a control panel and all the diode blocks.
The engine doesn't have an electric starter but does have an alternator and it does work. The regulator/diode module was bad so I grabbed a new one off A-zon for $8. This will keep the system battery charged and hopefully keep the battery voltage a little above static level when powering the weldernator field. If I get the pulley sizes and RPM correct, I should be able to run brushed power tools on this system without any difficulty.
The control panel will have gauges for welding output voltage, field voltage, battery/charging system voltage, a rheostat for controlling field voltage, a "weld" switch that powers the field, and remote kill switch for the engine. I'll also put an electrical outlet on it for running power tools.
On the way are rectifiers, a big heat sink, and some other small parts.
Here's a photo of the engine and pulley with the weldernator mocked up in place and wearing the wrong pulley. I'll put a 2.5" pulley on there when mounted for real and about a 31" 6-groove belt.
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