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Welding Shop

AC/DC Welding Questions


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  #21  
Old 04-30-2019, 07:34:49 AM
Tracy T Tracy T is offline
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Default Re: AC/DC welding questions

gonna have to have a clean up day, shop is a mess! need to get welder and armature out of the shop before i take the air hose to it, i know there is going to be a brown cloud once the air hose hits it! comuntator cleaned up nice!
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Old 04-30-2019, 06:05:58 PM
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Default Re: AC/DC welding questions

well it went on a diet today. everything about it is heavy, or really heavy! when i removed the control box I got a big supprise! I should have used the hoist, i didnt think it would weigh that much!!
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  #23  
Old 04-30-2019, 07:11:25 PM
Tracy T Tracy T is offline
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Default Re: AC/DC welding questions

a few more pictures, and the last one was real fun....
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  #24  
Old 04-30-2019, 07:22:26 PM
Tracy T Tracy T is offline
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Default Re: AC/DC welding questions

ok got some questions for the generator gurus. this is basically a heavy, no super heavy duty version of a automobile generator right? i am use to working with high voltage insulation and from what i am seeing the paper insulation is deterrating and would not cut the mustard in a high voltage application. but we are not dealing with high voltage, i think around 30- 40 VDC so it may be allright, what do you all think? most all of the insulation looks real good on the coils, its made onto the coils almost like a enamel. the windings ends in the second picture do show some wear, not bad though. looks like a varmit has chewed the cloth insulation in a few spots. what can i do about this short of a rewind? i was thinking about some of that liquid electrical tape that can be brushed on. thats it for now, gotta put everything back in the shop.
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Old 05-01-2019, 02:06:11 AM
cobbadog cobbadog is offline
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Default Re: AC/DC welding questions

Your getting right into it now Tracy and good on you for doing so and resurrecting it back to a usable welder again.
I know very little about the questions you have just asked and is one of the many reason I like to read these threads.

The best I do is I am starting to get into rebuilding some magnetos for my stationary engines. But you are jumping into it with both feet, I'm impressed.
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  #26  
Old 05-01-2019, 07:33:19 AM
Tracy T Tracy T is offline
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Default Re: AC/DC welding questions

cobbadog this is the easy part, its just a hunk of cold iron & copper in the beginnning. from here on it it gets slow, sourcing parts, waiting on parts and paying attetion to detail. and all of that cost money also, which is not unlimited! this welder will probably not get a full blown restoration, but i do hope to have it welding again! I kind of like to screw with people, their jaw drops when they see a hunk of junk sitting there and it looks much the same when i get done but works like it should. kind of like the trucers saying "chrome dont get you home." I wish i still had my contacts with the transformer shop i worked at, alot of what i need comes on a roll and i only need a few feet not a 100 feet. that company has been sold off two times since i left, and the place we bought our supplies from i think has went out of business.
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Old 05-01-2019, 11:22:55 AM
Tracy T Tracy T is offline
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Default Re: AC/DC welding questions

I cant believe i am going to try this, no luck finding the springs for the DC brushes, so off to buy some piano wire. we will just make em! I would have never thought that earlier this morning! I dont own a lathe, but i know where one is at! just a mile down the road. time to pull a favor from a neighbour.
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  #28  
Old 05-01-2019, 12:39:54 PM
Vanman Vanman is offline
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Default Re: AC/DC welding questions

Looking good so far! That motor armature "stator" looks pretty rough. But the generator looks pretty good.

The motor would freewheel if driven externally. It cannot generate if not connected to an AC source, or to some capacitors.

Yes, it is quite similar in construction to an automotive DC generator. Arc volts is probably ~40, but open circuit voltage is probably ~80 ish.

For the armature, ideally, you'd heat it up in a LOW oven to dry it out, then vacuum impregnate it with varnish. That transformer shop would have been ideal, but you should be able to find a place to do it.

How did you clean the commutator? Scotchbrite is generally recommended. It works great, and does not carry the risk of imbedding grit in the soft copper. That'll chew up the brushes.

Keith
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  #29  
Old 05-01-2019, 12:47:05 PM
Tracy T Tracy T is offline
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Default Re: AC/DC welding questions

keith i tried scotchbrite pad, wouldnt touch it! I bet i rubbed 45 minutes and it just wouldnt cut it, switched over to a very fine emory cloth like used to polish crankshafts and it still took some elbow grease but did clean up. use to do just about anything and everything @ the transformer shop, except winding. dipped, baked, fabrication, cut core steel, highvoltage bus work, low voltage bus work, taps aluminum and copper. I hated working with strip wound units though! i think everybody did.
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  #30  
Old 05-01-2019, 10:59:55 PM
Tracy T Tracy T is offline
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Default Re: AC/DC welding questions

well, like i said it slows down from here on out. some progress today locating spring material, and i made my first prototype and now i know what i need to make. my first was just made out of some wire i had laying around. i can see already the challenge is there as stiffer wire will have a learning curve to it! no piano wire in the county to be had! second runner up and i think it will work! throttle cable off of a push mower, stainless steel and free @ the landfill. we will see, i have 3 different materials to work with and all it cost was a little time. much needed time both on and off the progect, man yesterday wore my @$$ out!!!
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  #31  
Old 05-02-2019, 01:42:53 AM
cobbadog cobbadog is offline
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Default Re: AC/DC welding questions

My wife and I restore vintage tractors, stationary engines and mowers. Not all get the full treatment when restoring so I fully understand the theory behind get it running no matter what it looks like. We call that being in it's "working clothes".
As you have discovered the next step can be the most annoying, finding parts or a substitute. This is an ongoing exercise for some of our projects. It took 4 years to find the tractor we wanted then another 3 just to find a missing body part then found 2 of them and bought them both. Some parts can be almost matched perfectly and others need to be 'tricked up' a little. I found the right size bump stop rubbers for the front axle but the mounting bolt was too small. So with my little lathe I used a piece of round rod and bored a hole up the centre and machined the OD so I could thread them both. Now I screwed the rod onto the standard mounting bolt, pinned it in place so that it doesn't undo then threaded the OD and bolt it on.
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  #32  
Old 05-02-2019, 09:26:30 AM
Tracy T Tracy T is offline
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Default Re: AC/DC welding questions

hmm, now i am on the fence which material to use. I got to looking closer and it appears one is a brass type material, and i have the most of that couple hundred feet of it! its stiff, and about the right size. when you cut it there is no appearance of steel all the way thru. the gentelman that gave me that roll was elderly himself and he said it was something his dad brought home. its probably close the same age as the welder. he didnt know where it came from but said his dad worked in the coal mines. communication wire maybe?
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  #33  
Old 05-02-2019, 08:56:18 PM
Tracy T Tracy T is offline
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sorry folks, i got lazy today. but i did do alot of thinking today! I may have to become a cattelman, rancher whatever you want to call it tomorrow. neighbor needs help, no experience on my behalf! but i will try!!

Last edited by Tracy T; 05-04-2019 at 05:59:30 PM.
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Old 05-02-2019, 09:27:27 PM
Vanman Vanman is offline
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Default Re: AC/DC welding questions

What type of brush springs are you trying to reproduce? If they're the ones wound out of flat stock, perhaps the material for making clock springs would be helpful?
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Old 05-03-2019, 01:32:41 AM
cobbadog cobbadog is offline
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Default Re: AC/DC welding questions

Looks as if your communication wire might become commutator wire!
Good luck playing a cowboy or being a 'side kick' but I thought that is what cattle will do when your in the wrong place.
Another option to a clock spring is the recoil spring from a lawn mower recoil starter.
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  #36  
Old 05-03-2019, 07:32:53 AM
Tracy T Tracy T is offline
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Default Re: AC/DC welding questions

torsion springs is what it has, I will try to get a picture up before the farm work starts.
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Old 05-03-2019, 11:44:19 AM
Tracy T Tracy T is offline
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Default Re: AC/DC welding questions

cow trucks running late, got 2 tractor trailer loads coming! so i will be tied up the rest of today. i decided to try some of the stiffer unknown wire and i think its gonna work! here are a few pictures for your amusment. this is just a rough one when i do make them they will be wound neater.
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  #38  
Old 05-03-2019, 01:13:45 PM
Vanman Vanman is offline
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Default Re: AC/DC welding questions

Ah, yes, that kind of spring. I was visualizing something different. Looking good!
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Old 05-04-2019, 02:26:32 AM
cobbadog cobbadog is offline
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Default Re: AC/DC welding questions

Great work Tracy, they are similar to a clothes peg spring but they would be too strong I guess.
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Old 05-04-2019, 05:33:42 PM
Tracy T Tracy T is offline
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Default Re: AC/DC welding questions

the stainless steel i got was too soft, it made a beautiful replica but no spring to it! back at it with the unknown brass looking wire, got 4 made this morning and they are not quite as neat as i would like them to be, but should work! have to make 4 more, I may do that here in a little bit. i can get the tension all the same but the length varies some but its not critical because where each end fastens is a set point. in other words the spring is longer than where it pins. its hard to see in the pictures but one end was purposely longer to allow adjustment as the brushes wear, three slots in the side of the for lack of a better term rocker arm/ pusher. the other end just pases through two solid pins one on each side of the spring.
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