General Welding equipment - Revision history

HarryMann: /* MIG Modifications */

2010-08-07T00:26:12Z

MIG Modifications

← Older revision		Revision as of 00:26, 7 August 2010
Line 41:		Line 41:

	'''Smoother, more consistent feed'''<br>		'''Smoother, more consistent feed'''<br>
	To garner a reliable smooth spool rotation - and hence smoother wire-feed (so important), I finally found this solution works well - to stop the spool juddering, and allow the knurled pressure knob to be set and left (rather than be too ~~slack~~ or too ~~tight and~~ unwind ~~itself~~).		To garner a reliable smooth spool rotation - and hence smoother wire-feed (so important), I finally found this solution works well - to stop the spool juddering, and allow the knurled pressure knob to be set once and left alone (rather than be too tight or too slack when the spool might unwind).<br>
	The mod involves simply cutting a rubbing pad of scotchbrite to size, punching a hole in it and mounting it.. basically ''stops sticking spools!'' Welder = Clarke 151 TE		The mod involves simply cutting a rubbing pad of scotchbrite to size, punching a hole in it and mounting it.. basically ''stops sticking spools''. Welder = Clarke 151 TE

	[[File:Clarke_MIG_SpoolMod_01.jpg]]		[[File:Clarke_MIG_SpoolMod_01.jpg]]

HarryMann: /* Electric spot welding */

2010-07-27T00:57:04Z

Electric spot welding

← Older revision		Revision as of 00:57, 27 July 2010
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	=Electric spot welding=		=Electric spot welding=

	~~This~~ has been the welding process of choice for the mass production of automobile sheet-steel bodies and chassis for many years now.		''Spot'' or ''resistance'' welding has been the welding process of choice for the mass production of automobile press-formed sheet-steel bodies and chassis for many years now. These days robots weld car panels together very accurately and consistently and fast.

	Workshop spot-welders ~~are around~~, but tend to be a bit cumbsersome usually, and heavy... and expensive when new... very handy though to be able to manually electric spot a part panel or seam in-place.		Workshop spot-welders can be bought, but tend to be a bit cumbsersome usually, and heavy... and expensive when new... very handy though to be able to manually electric spot a part panel or seam in-place. They are expensive beacuse they carry large electrical current (for short periods) and thus require very heavy gauge copper electrodes.

	PS~~> mOre~~ & more people are reducing seam welding part and whole panels in place, resorting to modern high-tech adhesives, plus a few rivets or MIG spot welds.		[[File:Ckarke_SpotWelder_01.jpg]]

			The heat is created very locally, at a small diameter (circa 6~7mm) spot where the two sheets contact each other, by passing very high current through the joint, which presents very low resistance. The most intense heat is between the two surfaces, rather than the between the copper electrode and surface, hence the met area is at the join between the steel (having higher resistance there). the time is critical, usually of the order of a second or two, depending on sheet gauge and current capacity of the welder. The adjoining steel (usually) sheets have to have good contact surfaces, so are either bare metal or zinc coated, to prevent subsequent corrosion.

			This is the origin of the original usage of 'Weld-thru' zinc sprays, to simulate electro-galvanised steel sheets. Weld-thru high zin solid contents sprays can be sued ad hoc DIY when spot-welding repairs manually.

			PS. More & more people are reducing seam welding part and whole panels in place, resorting to modern high-tech adhesives, plus a few rivets or MIG spot welds.

	=Safety equipment=		=Safety equipment=

HarryMann: /* Electric spot welding */

2010-07-27T00:45:48Z

Electric spot welding

← Older revision		Revision as of 00:45, 27 July 2010
Line 113:		Line 113:

	This has been the welding process of choice for the mass production of automobile sheet-steel bodies and chassis for many years now.		This has been the welding process of choice for the mass production of automobile sheet-steel bodies and chassis for many years now.

			Workshop spot-welders are around, but tend to be a bit cumbsersome usually, and heavy... and expensive when new... very handy though to be able to manually electric spot a part panel or seam in-place.

			PS> mOre & more people are reducing seam welding part and whole panels in place, resorting to modern high-tech adhesives, plus a few rivets or MIG spot welds.

	=Safety equipment=		=Safety equipment=

HarryMann: /* MIG Modifications */

2010-07-26T21:44:46Z

MIG Modifications

← Older revision		Revision as of 21:44, 26 July 2010
Line 47:		Line 47:

	'''Better, more reliable earthing''' <br>		'''Better, more reliable earthing''' <br>
	I also decided to put a much higher pressure and heavier duty earth clamp on it (from previous experience of lighweight junk earth clamps letting a good welder down) and because it was easier, left the original.. therefore I usually connect both, so if one drops a good connection, it doesn't affect the current welding process critically. Earth ~~calmp~~ from Screwfix or Axminster Tools... beware, their heaviest one I can barely open with one hand, you need to be able to easily/quickly mount or adjust it.		I also decided to put a much higher pressure and heavier duty earth clamp on it (from previous experience of lighweight junk earth clamps letting a good welder down) and because it was easier, left the original.. therefore I usually connect both, so if one drops a good connection, it doesn't affect the current welding process critically. Earth clamp from Screwfix or Axminster Tools... beware, their heaviest one I can barely open with one hand (you really need to be able to easily/quickly mount or adjust it sinmgle-handed).

	[[File:Clarke_MIG_EartClampMod_01.jpg]]		[[File:Clarke_MIG_EartClampMod_01.jpg]]

HarryMann: /* Mini and non-refillable bottles */

2010-07-25T22:16:12Z

Mini and non-refillable bottles

← Older revision		Revision as of 22:16, 25 July 2010
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	The fuel-gas is based on propane, but is in fact a modified gas, such as MAP Pro or MAP+ which burns hotter and the oxygen is in a similar sized cylinder (both about £20 each). MAP Pro or MAP+ is also used solo in blowtorches for a slightly hotter fuel/air flame for e.g. plumbing. Those are however hot enough for genuine bronze welding without oxygen and a bespoke torch.		The fuel-gas is based on propane, but is in fact a modified gas, such as MAP Pro or MAP+ which burns hotter and the oxygen is in a similar sized cylinder (both about £20 each). MAP Pro or MAP+ is also used solo in blowtorches for a slightly hotter fuel/air flame for e.g. plumbing. Those are however hot enough for genuine bronze welding without oxygen and a bespoke torch.

	These (micro) welding kits (e.g. ~~Turbo2000~~ set pictured)) are very handy for occasional heating and brazing. True welding cannot be done, due to hydrogen embrittlement (due to the fuel-gas).		These (micro) welding kits (e.g. Turbo 200 / OxyTurbo set pictured)) are very handy for occasional heating and brazing. True welding cannot be done, due to hydrogen embrittlement (due to the fuel-gas).

	[[File:Turbo2000_01.jpg]]		[[File:Turbo2000_01.jpg]]

HarryMann: /* MIG Modifications */

2010-07-25T21:07:53Z

MIG Modifications

← Older revision		Revision as of 21:07, 25 July 2010
Line 40:		Line 40:
	==MIG Modifications==		==MIG Modifications==

	TO garner a reliable smooth spool rotation - and hence smoother wire-feed (so important), I finally found this solution works well - to stop the spool juddering, and allow the knurled pressure knob to be set and left (rather than be too slack or too tight and unwind itself).		'''Smoother, more consistent feed'''<br>
			To garner a reliable smooth spool rotation - and hence smoother wire-feed (so important), I finally found this solution works well - to stop the spool juddering, and allow the knurled pressure knob to be set and left (rather than be too slack or too tight and unwind itself).
	The mod involves simply cutting a rubbing pad of scotchbrite to size, punching a hole in it and mounting it.. basically ''stops sticking spools!'' Welder = Clarke 151 TE		The mod involves simply cutting a rubbing pad of scotchbrite to size, punching a hole in it and mounting it.. basically ''stops sticking spools!'' Welder = Clarke 151 TE

	[[File:Clarke_MIG_SpoolMod_01.jpg]]		[[File:Clarke_MIG_SpoolMod_01.jpg]]

			'''Better, more reliable earthing''' <br>
	I also decided to put a much higher pressure and heavier duty earth clamp on it (from previous experience of lighweight junk earth clamps letting a good welder down) and because it was easier, left the original.. therefore I usually connect both, so if one drops a good connection, it doesn't affect the current welding process critically. Earth calmp from Screwfix or Axminster Tools... beware, their heaviest one I can barely open with one hand, you need to be able to easily/quickly mount or adjust it.		I also decided to put a much higher pressure and heavier duty earth clamp on it (from previous experience of lighweight junk earth clamps letting a good welder down) and because it was easier, left the original.. therefore I usually connect both, so if one drops a good connection, it doesn't affect the current welding process critically. Earth calmp from Screwfix or Axminster Tools... beware, their heaviest one I can barely open with one hand, you need to be able to easily/quickly mount or adjust it.

HarryMann: /* MIG Modifications */

2010-07-25T21:02:49Z

MIG Modifications

← Older revision		Revision as of 21:02, 25 July 2010
Line 49:		Line 49:

	[[File:Clarke_MIG_EartClampMod_01.jpg]]		[[File:Clarke_MIG_EartClampMod_01.jpg]]

			'''NB.''' Oh yes, that warning label inside the door! Always take note of that! Cut the new wire dead straight across with side-cutters, then file or sand it to a nice smooth rounded shape, removing any sharp burrs... then feeds beautifully through without carving up the hose-liner.

			It's all about equipment maintenance, so its a genuine long term investment that'll still be working well in 10 years time...

	=TIG Welding=		=TIG Welding=

HarryMann: /* MIG Modifications */

2010-07-25T20:57:05Z

MIG Modifications

← Older revision		Revision as of 20:57, 25 July 2010
Line 46:		Line 46:


	I also decided to put a much higher pressure and heavier duty earth clamp on it(from previous experience of lighweight junk earth clamps letting a good welder down) and because it was easier, left the original.. therefore I usually connect both, so if one drops a good connection, it doesn't affect the current welding process critically. Earth calmp from Screwfix or Axminster Tools... beware, their heaviest one I can barely open with one hand, you need to be able to easily/quickly mount or adjust it.		I also decided to put a much higher pressure and heavier duty earth clamp on it (from previous experience of lighweight junk earth clamps letting a good welder down) and because it was easier, left the original.. therefore I usually connect both, so if one drops a good connection, it doesn't affect the current welding process critically. Earth calmp from Screwfix or Axminster Tools... beware, their heaviest one I can barely open with one hand, you need to be able to easily/quickly mount or adjust it.

	[[File:Clarke_MIG_EartClampMod_01.jpg]]		[[File:Clarke_MIG_EartClampMod_01.jpg]]

HarryMann: /* Modifications */

2010-07-25T20:54:59Z

Modifications

← Older revision		Revision as of 20:54, 25 July 2010
Line 38:		Line 38:
	BUT if you can only weld outside you'd probably be better with gasles		BUT if you can only weld outside you'd probably be better with gasles

	==Modifications==		==MIG Modifications==

	TO garner a reliable smooth spool rotation - and hence smoother wire-feed (so important), I finally found this solution works well - to stop the spool juddering, and allow the knurled pressure knob to be set and left (rather than be too slack or too tight and unwind itself). Welder = Clarke 151 TE		TO garner a reliable smooth spool rotation - and hence smoother wire-feed (so important), I finally found this solution works well - to stop the spool juddering, and allow the knurled pressure knob to be set and left (rather than be too slack or too tight and unwind itself).
			The mod involves simply cutting a rubbing pad of scotchbrite to size, punching a hole in it and mounting it.. basically ''stops sticking spools!'' Welder = Clarke 151 TE

	[[File:Clarke_MIG_SpoolMod_01.jpg]]		[[File:Clarke_MIG_SpoolMod_01.jpg]]


	I also decided to put a much higher pressure and heavier duty earth clamp on it, and because it was easier, left the original.. therefore I usually connect both, so if one drops a good connection, it doesn't affect the current welding process ~~criticaly~~		I also decided to put a much higher pressure and heavier duty earth clamp on it(from previous experience of lighweight junk earth clamps letting a good welder down) and because it was easier, left the original.. therefore I usually connect both, so if one drops a good connection, it doesn't affect the current welding process critically. Earth calmp from Screwfix or Axminster Tools... beware, their heaviest one I can barely open with one hand, you need to be able to easily/quickly mount or adjust it.

	[[File:Clarke_MIG_EartClampMod_01.jpg]]		[[File:Clarke_MIG_EartClampMod_01.jpg]]

HarryMann: /* MIG Welding */

2010-07-25T20:50:26Z

MIG Welding

← Older revision		Revision as of 20:50, 25 July 2010
Line 38:		Line 38:
	BUT if you can only weld outside you'd probably be better with gasles		BUT if you can only weld outside you'd probably be better with gasles

			==Modifications==

			TO garner a reliable smooth spool rotation - and hence smoother wire-feed (so important), I finally found this solution works well - to stop the spool juddering, and allow the knurled pressure knob to be set and left (rather than be too slack or too tight and unwind itself). Welder = Clarke 151 TE

			[[File:Clarke_MIG_SpoolMod_01.jpg]]


			I also decided to put a much higher pressure and heavier duty earth clamp on it, and because it was easier, left the original.. therefore I usually connect both, so if one drops a good connection, it doesn't affect the current welding process criticaly

			[[File:Clarke_MIG_EartClampMod_01.jpg]]

	=TIG Welding=		=TIG Welding=