Weldernator Mk. II, portable version
- Thread starter Ian
- Start date
F
freebullet
Guest
Nice work, Ian.
Since this has proven out maybe ya can start on the water fueled 1 ton 4x4. If anyone can....
Since this has proven out maybe ya can start on the water fueled 1 ton 4x4. If anyone can....
Ian
Notorious member
It doesn't look like it but I put in four more hours on this project today. Got a control panel fabricated and attached, made some brackets for the rectifier bridge and heat sink and got that mounted, hooked up a field control switch and rheostat, and did some rough wiring layout. Also installed a 120 VDC non-grounded outlet and fired the machine up to test the voltage and ran my DeWalt angle grinder for a few minutes. This thing will make 165 volts at full throttle so I dialed it back to about 2500 rpm to get 120 with the grinder running and it worked like a champ, hardly lugging the engine at all.
I still need to drill the panel for a 20-VDC voltmeter for the field control and a 200-VDC welding output control so I can see what I'm doing when tuning RPM (volts) and field voltage (output amperage) for welding and running power tools. I'm also considering mounting some panel plugs for the welding electrodes so I can reverse the polarity of the leads if I want to.
Still a lot of cleanup and looming to do with the wiring and some more parts to buy. Also need to fab a battery tray underneath the deck, make a permanent mount for the inductor coil, and work out some hooks on both sides of the control panel frame to store the cables.
I still need to drill the panel for a 20-VDC voltmeter for the field control and a 200-VDC welding output control so I can see what I'm doing when tuning RPM (volts) and field voltage (output amperage) for welding and running power tools. I'm also considering mounting some panel plugs for the welding electrodes so I can reverse the polarity of the leads if I want to.
Still a lot of cleanup and looming to do with the wiring and some more parts to buy. Also need to fab a battery tray underneath the deck, make a permanent mount for the inductor coil, and work out some hooks on both sides of the control panel frame to store the cables.
Bret4207
At the casting bench in the sky. RIP Bret.
If you ask me you're short on duct tape, hose clamps and you lack the required set of Vise Grips holding at least one high voltage electrical connection together that defines a true Red Green type fix. 
FWIW, I've found some 120v type tools, like angle grinders and drills, will run on varying voltages. They seem to do okay 10-15 volts +/-. Not sure how long they will last like that, but they'll work based on my observations when I let the needle get way above or below the "green" area on my PTO genset.
FWIW, I've found some 120v type tools, like angle grinders and drills, will run on varying voltages. They seem to do okay 10-15 volts +/-. Not sure how long they will last like that, but they'll work based on my observations when I let the needle get way above or below the "green" area on my PTO genset.
Ian
Notorious member
The grinder did fine on 70 volts, it just ran a little slower. I have a 2500 watt genset for running power tools but it's nice to have one-stop-shopping for power when rolling this out to do construction and repairs in the "Back 10".
I used Vise Grips on the battery posts to hook my small alligator test leads to, does that count? Some duct tape and hose clamps would tidy it up a bit...just wait, I'm not finished
I used Vise Grips on the battery posts to hook my small alligator test leads to, does that count? Some duct tape and hose clamps would tidy it up a bit...just wait, I'm not finished
Bret4207
At the casting bench in the sky. RIP Bret.
You are redeemed bud. As long as there is at least one of the 3 requirements met, you are okay. A little known fact is that if you have duct tape holding your boot together or a hose clamp securing a major component to your vehicle, or even enough electrical tape or zip ties doing something like keeping your glasses more or less in one piece, that will give you enough points to make Team Red Green! Sometimes even long standing members of Team Red Green turn out nice looking gizmos, gadgets and geehaws. We don't hold that against them if they did it using tools with duct tape holding a battery in a cordless drill, baling wire holding the head on their hammer or zip ties keeping their belt in one piece. It's the little things that count!
Ian
Notorious member
I forgot to update this again with finished photos.
Got the control panel finished and all it lacks is a battery rack underneath, probably won't even mess with that at this point though. This thing is AWESOME!
Rolled it down to the front gate a while back and welded some walk-through gate hinges in place. Ran a DeeWilt angle grinder no problem, much smoother than on AC.
Got a 200VDC and 20VDC meter installed in the control panel so I can dial in field voltage and monitor output voltage for repeatable settings.
The result:
I'm no pro welder but the machine does great.
Got the control panel finished and all it lacks is a battery rack underneath, probably won't even mess with that at this point though. This thing is AWESOME!
Rolled it down to the front gate a while back and welded some walk-through gate hinges in place. Ran a DeeWilt angle grinder no problem, much smoother than on AC.
Got a 200VDC and 20VDC meter installed in the control panel so I can dial in field voltage and monitor output voltage for repeatable settings.
The result:
I'm no pro welder but the machine does great.
