Home Sign Up!

Explore Community Submit

Build a Microwave Transformer Homemade Stick/Arc Welder

by stasterisk on December 23, 2007

Table of Contents

intro: Build a Microwave Transformer Homemade Stick/Arc Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

step 1: Dissect the Microwaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

step 2: Prepare the Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

step 3: Get some 24 foot chunks of ten-guage wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

step 4: Wind the new transformer secondaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

step 5: Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

step 6: Wire your two transformers together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

step 7: Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

step 8: Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

step 9: Thick Rod Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

step 10: Welding Stainless Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

step 11: Dimmer Control and Welding Thin Wall Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

step 12: Other Welders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Advertisements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Customized Instructable T-shirts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/
intro: Build a Microwave Transformer Homemade Stick/Arc Welder
I had no idea making a DIY welder would be so easy to do. And, it's pretty much FREE!

Additionally, the stick welder you get is definitely better than anycheap commercial welder you can buy.
Why is this homemade thing better than something you can buy? Because when you factor in shipping and labor and the little bit of retail markup - the companies that
make typical cheap buzz boxes will skimp on copper as much as possible. Whereas you can use enough copper in this to make something really juicy, and still spend
less, to nothing, compared to a store-bought arc welder.

So here's what you need to build a welder:

- Two beat up old microwaves
- Some 10 gauge wire
- Wire nuts

People throw out microwaves all the time, if you keep your eyes on the curbs.
Or, you can get microwaves at the local thrift store for $10 each.
Try the warehouse that processes donations - they have to pay to get rid of tons of broken ones.

Stuff you need for welding:

- Welding helmet ($16 and up)
- Welding rods ($6)
- Vice grip or purpose-built electrode holder ($6 for either)
- C clamp for grounding clamp
- Gloves
- Thick nonflammable (leather) clothing that will cover your arms

Disclaimer: High Voltage ELECTRICITY and lots of CURRENT! Heat, electrocution, and DANGER! You could die and you could go blind.

That said, try this at home!

Here are the really good how-tos that this project is informed by:
build a 70 amp welder
the tiny tim welder by tim williams
home made welding machine (via afrigadget)

Dan Hartman's how-to is good for reference, too.

And here's the quickest way to make a DC welder with a bunch of 12 volt batteries.

Image Notes
1. sparks! The good kind, from the weld, not the bad kind from the welder.
2. me welding
3. call me Flashdance.

http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/
step 1: Dissect the Microwaves
Invite your non-hardware oriented pals over to help help dissect your donor appliances.
They'll love it. David Grosof donated one of these microwaves under the condition that we take it apart together.

Good safety tip:

You'll find a gigantic capacitor inside the microwave. It looks like a metal can with two tabs on top.
Short it out to make sure it doesn't have any leftover charge on it, before you poke your hands anywhere near. Just put a screwdriver or something metal you aren't
connected to, across the two metal terminals shown here.

Image Notes
1. microwaves are full of surprises - smelly sneaker surprise!

http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/
 Image Notes Image Notes
1. microwave guts! 1. Big Cinder: earth after global warming?
2. transformer: save this and use it! 2. very long screwdriver
3. front panel electronics: recycle! 3. five-bit switcheroo screwdriver
4. MAGNETRON: coolest name ever! 4. Star Simpson's dismantling-microwaves face
5. AC power cable: save this and use it later!
6. fan: recycle!

Image Notes Image Notes

1. magnificent fuse 1. waveguide: the magnetron drools its 2.4GHz microwave rays into the oven
area, through this.

http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/
 Image Notes
1. this is the magnetron. it's good for tronulizing magnetoids. by which I mean, it
produces 2.4GHz radiation.

step 2: Prepare the Transformers

Chop and and knock out the secondary (thin wire) windings.
Don't nick or damage the primary windings in any way.

If you do, you could create shorts where two windings conduct to each other, allowing electricity to bypass certain parts of the coil, making effectively a smaller coil, and
creating something different than what you expect at the output. Or, you might chop the connection entirely, ruining the primary. So do your best to keep it intact.

Image Notes
1. Primary windings - powered by the gods of walljuice. Don't harm these in
any way.
2. Low-voltage winding for filament current or somesuch thing to feed the
magnetron. Remove this.

http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/
 Image Notes
1. use a sharp chisel to cut the copper winding

Image Notes
1. after chiseling, pound the wiring out. be really careful to keep the primary
intact, with no nicks.

http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/
 Image Notes
1. the disemboweled remains of the transformer secondary coils. This is at least a
few pounds of pure copper. Sell it to the scrap yard for $4.50 a pound and take a
nice trip.

http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/
step 3: Get some 24 foot chunks of ten-guage wire
We scavenged some heavy wire from an old powerboat the owner was scuttling.
We stripped the outer jacket off and separated the inner conductors to wind new secondaries
on our transformers.

Video

Image Notes
1. Star is skinning the 24 foot anaconda
2. this bike innertube creates tension for stripping away the wire jacket. the other
end of the cable is C-clamped to the table.
3. Screwdriver pounded into the pavement temporarily.
4. Mr. Fireface is mobile now. A cozy glow whereever you're working.

http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/
step 4: Wind the new transformer secondaries
We wound 20 turns of 10-guage wire on each transformer. That's just about how much wire would fit into the available space. It took a little over 20 feet of wire each.

tip: draw tally marks on your table to keep track of the number of windings.

How does a transformer work?

The primary winding is an electromagnet connected to alternating current.
The humming magnetic field of the primary induces a current to flow in the secondary winding. If both windings have the same number of turns, the output voltage is the
same as the input.
(minus a smidgin due to eddy currents, resistance, etc.)
If the secondary has more turns than the input, its output voltage is higher. That's the type of transformer you started out with.

OUTPUT VOLTAGE = INPUT VOLTAGE * (NUMBER OF SECONDARY TURNS) / (NUMBER OF PRIMARY TURNS)

Our primary has 100 turns and gets connected to 100 volts AC. We're winding 20 turns on the secondary, so we'll get about 20 volts out.

The available POWER STAYS THE SAME regardless of what the output VOLTAGE is.
POWER (WATTS) = AMPS * VOLTS

If the primary is made take 1000 watts (100 volts * 10 amps) out of the wall, we'll be able to take 1000 watts out of the secondary. With 1/5 of the windings, we can draw
50 amps out of the secondary.

That's the cartoon version with play numbers anyway.

Over here in our shed full of reality we've got two of these beasts in series and plan to short the outputs through a welding rod like Jennifer Beals.

Let's just say we're going to pull a whole lot of amps, which is why we need to wind our secondary with such thick wire.

The copper conductor in ten-guage wire happens to be 1/10" (0.1") in diameter.

Here's a table of conductor diameter, guage, and current rating.

http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/
 Image Notes
1. use a flat bar as a wedge to make space for more windings.

step 5: Schematic
It's a pretty simple circuit.
In fact there's nothing in it except wire!

We'll take two transformers and wind low-voltage secondary windings on them with thick wire.

We'll put the secondaries in series with our welding rod and workpiece.
We'll plug the primaries into the wall.

I really like the way aaawelder put it: "do not include yourself in this circuit"

Image Notes
1. welding rod
2. ground clamp
3. workpiece
4. New 10 guage low-voltage high current secondary windings
5. electrode holder
6. To use this unit on 220 volts put the primaries in series rather than parallel as shown here
7. existing primary windings

http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/
step 6: Wire your two transformers together
Why do we use two transformers?
Just one of these isn't big enough to make a really juicy welder.
If you happen to find a big enough transformer somewhere, feel free to use that.

Here's how to hook up two transformers.

First we wire both primary windings in parallel to the wall cord.
Then we wire the thick secondaries in series so they both"Push and pull" in the same direction.

Video

Video

Video

http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/
 Image Notes
1. Wire Nut
2. Three wires twisted together

Image Notes Image Notes

1. If the bare part is too long the wire nut won't cover it. If the end is too pointy 1. To everything turn turn turn there is a season turn turn turn and a wirenut for
the threads inside the wire nut might not grip it well. Cut it square if you're every purpose such as cover twisted wire ends and shoot through conduit-
concerned. compressed-air guns at rats.

http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/
step 7: Test
Get out yer voltmeter:

Here's the test to make sure the secondaries are both pushing the same direction.
Our two secondaries in series produce 38volts AC with no load. That seems about right.
If they'd phased wrong it could have been fixed by reversing the wiring to any winding.

Where Tim says "out of phase" in the video, he means "in phase". That is, the center tap should be less than the outer two leads, and if things weren't that way, the
transformers would be fighting each other, or phased wrong.

Video

http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/
 Image Notes
1. Non conducting shoes. Not standing in a puddle of water.

Image Notes Image Notes

1. Electrical safety - keep one hand behind your back or in pocket so you don't 1. Hi! I'm MR. Baby tongue fun toy!
accidentally short across your heart by carelessly grabbing two wires. 2. Come here often?

http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/
 Image Notes
1. check the heat - these didn't really get warm, which is a great sign!
2. Radioshack autoranging multimeter. The best deal I know of for a little meter.
Why hasn't progress happened?

step 8: Weld
holy cow, it works!

We wanted to add a series inductor to give the unit more "inertia", but it didn't matter!

Here's Tim welding with some of those.

Video

Built your welder, but not sure how to weld? Check out the instructional videos on youtube - search "how to arc weld". They're very good.

Here's Star striking an arc.

It welds great with these thin 1/16" 6013 rods. Even better with 3/32" 6013 rods.

http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/
 Image Notes
1. scratch start technique
2. Awesome first weld bead!

Image Notes Image Notes

1. electrical connection, stick, and vice grip to hold it all together (all electrically 1. ground clamp
active)

http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/
 Image Notes
1. insulated glove for grabbing the electrically active vice grip

Image Notes
1. sparks! The good kind, from the weld, not the bad kind from the welder.
2. me welding
3. call me Flashdance.

step 9: Thick Rod Test

Those skinny 1/16" electrodes cost about twice as much as thicker ones.
We wanted to see how our welder works with thicker electrodes.
The next size up is 3/32", but we got a box of 1/8" 6011 electrodes.
When we pulled one out of the box we both said "wow, that's thick".

We fired up our welder and I welded this bead across the diamond plate with 1/8" rod.
The arc was pretty short but it burned in well and felt pretty good once I got used to it.
I had to shove it in a bit more than I'm used to to keep the arc going, but sticking wasn't a problem. I welded a long bead and used up more than half the rod without
stopping.
That's the long weld in this photo.

Then I set the "torch" in this plastic tub so it wouldn't short out to anything.
I checked the transformers, and they didn't even get warm!
3/32" rods are less likeley than 1/8" to blow a circuitbreaker though. For your first welds get 3/32" 6013 rods.
6011 rods have thinner flux and make it easier to see what the metal of your weld is doing, but tend to spatter a bit more.

The next picture is for reference, from

hobartwelders.com

Udate 4/16/2008:
This is now my favorite welder. I made new leads for it from a pair of jumper cables. I left one alligator clamp on for a ground clamp, and added a $6 electrode holder. I've
taught a bunch of people to weld using it.
The next photo is Ita welding for the first time, making an awning frame. That project was welded with this welder by total beginners using 3/32" 6013 rods. As you can
see we have every other kind of welder, but the homemade ones are more fun.

http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/
 Image Notes
1. It burns back into the coating, making it easy to maintain enough distance.

http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/
step 10: Welding Stainless Steel
We needed some brackets for Solara's mizzen mast.
So we went to the welding store and bought some 3/32" "Hobart Smootharc+ 316L - 16" stainless welding rods. They're only 12" long because stainless has high
electrical resistance and they get really hot.
After much designing and sketching Victor, Kenny, and I cut, drilled, bent and welded these brackets. Very easy. When it cooled the flux went "tik" and fell off the weld.
The dark area around the weld is soot from the flux.The welder could have handled much thicker rods due to stainless' high resistance and low thermal conductivity.

Important:
Use a fresh grinding wheel on stainless, or one that you only use on stainless.
You'll get rust if you use any abrasives that have been used on non-stainless steel. Same for the wrong wire brush. It will smear rustable iron on the stainless, and due to
galvanic effects it'll rust quick if it gets damp.

Hooray! Where did I get the idea you needed TIG for stainless? Stick welds on stainless are just great!

http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/
step 11: Dimmer Control and Welding Thin Wall Tubing
The welder was too hot for thin-walled tubing frames, I kept melting holes even with the 1/16" 6013 rods. So I plugged the welder into a variac dimmer and turned the
power down about 30%.
That gave me very fine control over power. Marc Lander and I did some very nice welds as seen here. After a few we got good enough to do the same welds with 3/32"
6013 rods and no dimmer and not burn holes.
More tricks - I used my left hand to feed a piece of mig welding wire into the weld to add more metal in and soak up the heat. Here's Marc doing that. Any wire is fine for
this, coathangers are traditional for muffler work. Sand off the paint first if you don't like fumes.
Stopping to eat lunch helped a lot also. Your welds won't be good when you're shaky and tired.

I got my variac for free, don't buy one for this, they cost as much as a welder.
A solid-state dimmer that's rated for inductive loads does the same thing and costs a lot less.

If you're feeling particularly fancy, you can add in your own scr-based switching circuitry to vary the power, like this guy did.

Image Notes
1. Nice Weld
2. automobile jumper cable ground clamp

Image Notes
1. Darth Vader doing crafts with his lightsaber on the weekend

http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/
 Image Notes
1. Mr. Variac a.k.a variable center-tapped autotransformer
2. Jumper cables
3. jumper cables. How many times in your life can you pull apart a zip-cord this
big?
4. handy welding magnet
5. Handy non-vicegrip electrode holder should bring great joy to safety lovers
everywhere
6. rewound microwave transformers
7. Your pal ms. Wire Brush. Brush rust away before welding, brush flux away after
chipping.
8. Your pal ms. Hammer. Use to chip flux and peen the weld to reduce stress from
weld freeze contraction

step 12: Other Welders

Folks have sent me a few photos and videos of welders they've built off of this instructable. I want you to be able to see them too, so here they are!

Here's a video I got from Paul du Buf, of the Netherlands (nice case, Paul!)

Video

'

Cheyyne said:

Hey there, here's my welder based on your instructabletion. It outputs 35.5v, because the
transformers were a little smaller than yours I think (couldn't wind a single more turn). So far I
have managed to lay down gobs of metal on various steel objects in my garage, but I still suck
at welding. Luckily I rented a nice welding video from Smartflix that had good reviews, hopefully
that'll give me some insight into the process. I did manage to lay down a 1" bead though! The
whole thing is going into a tacklebox housing.

Props for a great instructable. Thanks for it!

llamafur followed with:

Heres another one, same basic welder, but its housed in a .50 cal ammo can. Looks pretty
sweet. Its relay controlled ( two 15 amp HVAC control board relays wired in parallel) , I
measured 24 volts ac across the output wires.its also sorta heavy, 30 pounds.

http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/
 Image Notes Image Notes
1. llamafur's welder 1. llamafur's welder

Image Notes Image Notes

1. this case is metal, so it should be connected to ground. 1. llamafur's welder
2. llamafur's welder

Image Notes Image Notes

1. Cheyyne's welder 1. Cheyyne's welder

http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/
 Related Instructables

Homemade Handy Tricks 7: How to Weld - Hand Cranked How to Get

Awning and Bike Mods and TIG Welding by Cheap or Free
Golfcart + Spot Welder by Storage Rack by Document Small 110 volt
Projects by stasterisk Hardwood
Jumpercables = jds1969 TimAnderson Shredder by arc welder
TimAnderson Lumber by
DC Welder by TimAnderson (NYDG) by TimAnderson
TimAnderson Kdemon

Advertisements
Customized Instructable T-shirts

Comments
50 comments Add Comment view all 201 comments

cleghorncreations says: Aug 14, 2008. 7:11 AM REPLY

I'm not sure if my last comment worked. Basically, I tried this with two transformers and got about 40 volts out total. I am trying to weld with a 3/32 rod. I am
having a lot of trouble with it sticking. This may just be my inexperience at welding. Also when I did get an arc started and maintained, I laid a bead for about
5-10 seconds and the breaker tripped.

What determines the amount of current that the welder draws? If I added more turns and got more voltage would it draw too much current for a 20 amp
circuit? I saw another homemade welder where he recommended 70 volts. Wouldn’t that draw way more current since the resistance would be the same?

sullidave says: Oct 3, 2008. 12:41 PM REPLY

I tripped a couple of breakers the first time. I solved that problem by plugging each transformer into outlets on seperate breakers. I then had to reverse
the current direction on one of the transformers.
The rod sticking problem could be helped by trying a variety of different rod types and using the one that works the best for you. Since my welder is not
adjustable (yet), I have been using 7014 rods.

radroy92 says: Sep 19, 2008. 6:41 AM REPLY

AAAwelder http://www.geocities.com/aaawelder/ has instructions for winding the secondary the same direction as the existing primary winding on each
MOT. You didn't mention this. Isn't it important?? Or not??

sullidave says: Sep 1, 2008. 6:07 PM REPLY

Thank you very much for this instructable. My welder works great. I've been able to get good penetration and produce some nice beads using 3/16 rods.

I did a couple of things different:

Puchased a rod holder at a welding supply store.
Used heavy duty jumper cables for the cables.
Added a switch to turn it on and off.
Made a nifty enclosed case out of a microwave.

I think I lost count when re-wrapping the transformers. I believe there is 21 on one and 20 on the other. It doesn't seem to make a difference.

stasterisk says: Sep 1, 2008. 6:35 PM REPLY

awesome! congratulations on your new welder!

do you have any photos of your welder, and the welds you made?

http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/
 sullidave says: Sep 7, 2008. 10:51 PM REPLY
I hope this works, here's some photos.
I don't have the final pictures.
I enclosed the box more and remounted the switches later.
-dave

dionysus2008 says: Sep 7, 2008. 10:51 AM REPLY

in preparing my transformer, i used my disc grinder and grind off the welding at the sides and just hit off the bottom of the core. then i side out the coils. its
seems like a waste to destroy a perfectly good secondary coil so i kept it and dropped in my primary back and used some heavy duty welding wire to wrap
my secondary, oh its much much easier to wrap it with the bottom of the core gone then when i was done just bolt it up and ready for use

Plasmana says: Aug 25, 2008. 1:33 PM REPLY

Wow! Cool instructable! I really like it, I will build one when I get a transformer!
And flashdance is really bright!

jacobevolved says: Aug 11, 2008. 8:44 PM REPLY

LOVE this! If I understand electricity (And I'm not sure I do) If I clip the negative to a whole car(the body) ould it pull more electricity from my house in order
to saturate the car in order to create a generous enough pull(spark/arc) to actually cause welding? aka would it be more efficient/safer to remove a weldable
piece from the car before working on it?
Thanks

heavy.metal.nguyen says: Aug 11, 2008. 3:35 PM REPLY

You kinda sound like Tim Anderson! Very nice Instructable by the way.

craz meanman says: Aug 3, 2008. 8:36 PM REPLY

how come you aren't being shocked? or is the handle to the the thing holding the welding stick insulated? will i be able to tell if the "phasing" is correct by trial
and error, without a voltmeter thing?

stasterisk says: Aug 7, 2008. 1:17 AM REPLY

It's 40 volts, which is below the threshold for conducting across your skin.

I'm also being careful and not grabbing both leads. The temporary leads aren't insulated, so it's kept in a plastic bucket. The real stinger and clamp are
insulated.

I suppose you could check the phase without the voltmeter, and run the risk of melting your secondaries. If it doesn't weld, it's probably out of phase (0V
between the leads).

craz meanman says: Aug 8, 2008. 5:56 PM REPLY

thanks!

http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/
 stasterisk says: Aug 8, 2008. 6:25 PM REPLY
I should add - voltmeters are aroud $15 anywhere.

The plastic bucket is primarily to keep the welder from shorting.

handydave937 says: Aug 7, 2008. 5:28 PM REPLY

This is a great project, but as an electrician I need to throw in 2 things, first understand how to use Ohms law and half of your questions on current and
voltage will be answered.
Second opening circuit breakers and "modifying" them is a huge, huge risk. The wire feeding outlets in most homes is 14 gauge which is rated for 15 amps.
Slapping a 30 amp breaker on that circuit will melt the wiring in the walls and start a fire. If the insurance company determines the circuit was tampered with
they will not pay out the fire claim.

If you need a 30 amp circuit run new wire from the breaker box to the plug using 10 gauge wire. Better yet call an electrician.

jdpower says: Jun 17, 2008. 7:57 PM REPLY

Can I use 8ga. stranded insted of 10ga. solid ?
Also what if I move on down the scale to a larger wire?

stasterisk says: Aug 7, 2008. 1:17 AM REPLY

Yes, bigger guage is always good. You may have a hard time stuffing it in the gap of the secondary, though.

Derinsleep says: Jul 26, 2008. 8:58 AM REPLY

nothing,you will just be able to get more amps from it

craz meanman says: Aug 3, 2008. 8:45 PM REPLY

oh, and what happens if you DO nick the primary?

stasterisk says: Aug 7, 2008. 1:11 AM REPLY

electricity shorts across the coil.
now the transformer primary appears to have fewer turns.
your voltage drops.
heat increases in the primary, and the lacquer insulation begins to burn.
a lot of smoke. your welder stops producing power.

microwavedisplayDOTcom says: Jun 23, 2008. 12:18 AM REPLY

If you get steel shavings stuck in the corneas of your eyes, the doctors have a good chance of getting them out with very strong magnets.

But if you get copper or other non-magnetic shavings or chips stuck in your eyes, you'll have to go under the knife.

Safety glasses are so much cheaper!

Use 'em!!

SuperJesus says: Aug 6, 2008. 6:32 PM REPLY

Oh man, reading that cracked me up. Mostly because not 3 days ago I decided "pffhhh, i don't need stupid goggles, I'm just cuttin a plastic tube with my
dremel."

Not 20 seconds into cutting, shards of pvc pipe fly up and make love with the little space between my eye ball and eye lid. Sharp, jagged little pieces that
took 4 days and about 2 million blinks to get out.

Not a fun 4 days people, not fun at all. ALWAYS wear your glasses people.

And no, i didn't go to the hospital. Being poor, i was left with two options 1:get plastic shards outta my cornea or 2: be able to eat for the next two weeks.

Hunger won.

dman2two2 says: Aug 6, 2008. 6:03 AM REPLY

Does anyone know what kind of variac dimmer I should use?

http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/
 Quadranut says: Jul 16, 2008. 2:12 PM REPLY
I was wondering if a single tranny would suffice for 1/16th inch thick and thinner steel. ?

stasterisk says: Jul 16, 2008. 3:15 PM REPLY

Hmm - so, just one transformer would mean an increased current, which would be a lot hotter than the two beefy ones.

I'd go in the other direction! Either use a dimmer to attenuate the voltage before the transformers, or use more transformers to decrease the current at
the output.

llamafur says: Jun 28, 2008. 1:10 PM REPLY

I got some more stuff for my welder, and had a little too much fun with a label maker.

llamafur says: Jul 14, 2008. 11:27 AM REPLY

Here are some actual things I made with my welder.
Lots of "garden art"
A grinding rail
Slag hammer, pick
Mini Staff of DEATH
and a 240 volt outlet I installed.

http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/
 Danielro10 says: Jul 9, 2008. 10:14 PM REPLY
hey, i have built and tested a little bit with, my microwave oven welder and i have put a fan on it, how hot are the transformers suppose to get? iam worried,
and also do you think that adding another transformer would bring up the AMPS ?

Luki101 says: Jun 23, 2008. 5:04 PM REPLY

Would it be possible to weld with a flyback transformer?

llamafur says: Jun 28, 2008. 1:13 PM REPLY

no, the windings in a flyback transformer are hair thin, and would melt. there is also not enough amps being put out by the flyback transformer. it could be
used as an arc starter.

Luki101 says: Jun 30, 2008. 6:16 PM REPLY

oh, alright, thanks = ]

microwavedisplayDOTcom says: Jun 23, 2008. 12:15 AM REPLY

Where are those safety glasses?!

Please use safety glasses when using power tools, chiseling, or hammering.

microwavedisplayDOTcom says: Jun 23, 2008. 12:13 AM REPLY

As soon as you get the cover off, the next step should be to discharge the high-voltage capacitor.

Getting zapped by any stored charge in a high-voltage capacitor is not really the dangerous part in and of itself.

What's most dangerous is when you jerk your hand back and get slashed by the sharp edges on the metal in the innards of the microwave.

While a microwave that's defective or has gone a long time without having been run is not likely to have a stored charge, it's better to be safe than sorry.

Using a screwdriver with an insulated handle, short the blade across the two terminals of the capacitor.

If you have any doubts about how to do it, refer to this link:
http://www.gallawa.com/microtech/safety.html

http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/
 Have fun, but be safe!

William E. Miller, AS-EET

[email protected]
http://www.microwavedisplay.com

The Lightning Stalker says: Dec 27, 2007. 2:01 PM REPLY

I think you also need to leave in the "shunt" laminations - the stacks of metal plates that are between the primary and secondaries.

jdpower says: Jun 17, 2008. 7:51 PM REPLY

Uh oh. Shunt? How much trouble am I in if i have allredy removed these?

The Lightning Stalker says: Jun 18, 2008. 9:00 PM REPLY

It depends on how well the transformer is made, but you're probably going to overheat it and blow your circuit breaker every time you try to strike an
arc.

jdpower says: Jun 19, 2008. 11:00 PM REPLY

Is it posable to replace these and with what?
Thanks

trigalg693 says: Jun 20, 2008. 10:36 PM REPLY

If you have them you should be able to put them back in I think.

The Lightning Stalker says: Jun 20, 2008. 11:45 AM REPLY

You're going to have to start over with a new transformer. Chances are the laminations from a different one aren't going to fit right.

trigalg693 says: Jun 19, 2008. 10:50 PM REPLY

Meh I'll make another post.
I'm pretty sure you can saw or cut using other methods the welds holding the "I" part of the transformer to the "E" part, which would allow you to pull the coils
out (have to cut off any attachments to the steel part of the transformer first) then you can wind the new secondary more easily, then just put the primary
back on and somehow get the I to stay on. The tinytim carbon arc welder was made like this and has a picture showing a C clamp holding the transformer
together, but maybe you could use lots of packaging tape or something.

I had ambitions even before I saw this, went ahead and cut into the coils. Only after I wasted a lot of time cutting it and trying to get the stuff out did I look
closely at the transformer, and I realized the welds did nothing but to hold it together, and simply cutting 2 of the welds holding the "I" on would allow removal
of the windings.

digitaldreams says: Apr 14, 2008. 8:13 PM REPLY

Was in the tv biz for years and now work as a welder since tv repairmen dont get much work in this throw away age have built a welder but must tell you if
you build this unit for gods sake and your own enclose the coil in a non conductive box and use large woven wire 6 to 8 guage from the transformer to the
rod holder, and splurge for a insulated welders rod holder at your hardware store or you may be another Darwin award winner.These coils put out enough rf
with the voltage to burn a hole through your hand I know got careless once might not kill ya but after one of those shocks ya wont feel like runnin the 440

stasterisk says: Apr 14, 2008. 9:14 PM REPLY

thanks..
so, an insulated box works just as well as a grounded case. Check out the boxes others have used, in photos later in the comments. The ammo can is
my favorite!

I'm not sure what you mean about being burnt by the "RF" - and 20 volts won't shock you or 'burn a hole through your hand'.

ramses says: Jun 18, 2008. 2:03 PM REPLY

i think he is referring to the 2000v that is put out on the original secondary. search youtube for "burning stuff with a MOT" and you will know what he
means. also, in his instructable, it puts out 40v which can shock you pretty good.

srainsdon says: May 19, 2008. 9:49 PM REPLY

RF stands for Radio Frequency and YES it can burn I saw what hapond to a cat that walked in front of a microwave Antenna.

http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/
 ramses says: Jun 18, 2008. 2:04 PM REPLY
they are real, but 50/60hz isn't rf. you are thinking tesla coils...

llamafur says: Apr 22, 2008. 3:09 PM REPLY

thanks, I tried it out with the 3/32 and the 1/16 rods, the 3/32 rods definitely work better for mine, but I'm still learning. In wood shop, I asked my
instructor to teach me how to weld. later after school I was taught not just how to weld, but how to use the plasma cutter. I might need to add some
more cooling fans to mine.

llamafur says: Apr 22, 2008. 5:18 PM REPLY

correction the 3/32 electrodes don't work at all, the 1/16 ones work the best.

jdpower says: Jun 17, 2008. 8:06 PM REPLY

If you bare the tops of the transformers.(removing the clear coat)
place them top to top, then power one PRI.
You will fiend that the unpowerd transformer has an out put.
My ? . Is the field from the powered PRI. strong enuf to support two seconderys?

jdpower says: Jun 17, 2008. 8:27 PM REPLY

Thinking a little .
The power from the single PRI. would be shared buy the secondery wiendings.
Just kinda hit me like that.

fatcat0491 says: Jun 16, 2008. 5:10 PM REPLY

llamafur how did you add a Breaker into the welder please help me

view all 201 comments

http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/