Finally got this welder conversion done. From my last post here....I'm converting a cheapie HF fluxcore welder from AC to DC in the hopes of improving it.
Soldering the wires together. Used copper pipe for the connectors and it was a bit hit and miss. Corrosion on the inside unexpectedly prevented good contact in a couple spots, but it worked out in the end...
Wiring everything through the rectifier and capacitors...I ended up using an old electric box to hold the extra components. It worked well and bolted nicely onto the end of the welder. Some guys get the stuff inside the box, but there wasn't enough room for what I was working with....
Everything is wired, connected, and ready to test....
I wanted my brother to make the first test because it had been his welder. Since he was used to it, he would be able to tell how much improvement there actually was.
In my brother's words.... "I deem this a 100% success. I am impressed." The stuff on the left is the previous way it welded. They call it chickenshit. On the right was the first test, an actual bead. The weld also had good penetration compared to hardly any before. The piece heated up to red hot. My brother then got out his nice Lincoln to compare it. (I think this welder did just as well)....
Here it is all together. I'll paint the electric box black and put in some venting slots....
I have this extra capacitor that I also will add. One guy said he'd put in 7 of them if he could fit them, so apparently the more the better...but as it is I'm a happy camper...
