Help with cheap welder

[gregthomas]

Ok, I'm a poor guy and someone has given me a cheap Campbell Hausfeld WF2000 welder. The only problem I have with it is even the low setting (only has high and low) is too hot for the sheetmetal work I want to do on my car. Is there a way to modify the welder to adjust the voltage/current say with a potentiometer? Or do I have to change the transformer out to something different. I'm great with electronics. Any help would be appreciated.
Thanks,
Greg

 

[shenion]

If it is a flux-core (gasless) only welder there is not really anything you can do. Flux wire runs hot.

If it can be converted, then using gas and solid wire would work better.

 

[^neo^]

a smaller wire guage will also help. If the wire is thicker than the steel you're welding then you'll have trouble!

 

[TonyWilk]

How about a F***ing big diode in the input supply... it'll run on 1/2 phase and half the current.

I don't even know if this is a sensible suggestion or not

Yours,
Tony Wilk

 

[shenion]

How about a F***ing big diode in the input supply... it'll run on 1/2 phase and half the current.

I don't even know if this is a sensible suggestion or not

Yours,
Tony Wilk

Great way to burn up the transformer; the back EMF will blow the diode first anyway.

Also, lowering the power will likely cause the wire to not arc properly. Will just coil up in a red pile.

 

[gregthomas]

Thanks for the help guys. I'll try the smaller wire. Something like Tony suggested was what I was looking for. I've worked with a variable AC supply before when working on microwaves and such, turning them up slowly to make sure there are no short circuits, and I wondered if running the welder on one would be a sensible thing to do. I could then turn down the AC until I get what I'm looking for. Does this sound like an option?

 

[Jimbob]

I have the same welder, and I've used it to do some cab-corners and whatnot. Worked well, I just had to tack-weld the panels a little at a time. As fas as it running hot, the easiest thing you could do is plug it into a long extension cord, that would reduce the heat output. Also make sure you are using the .030" flux-core wire.
If you want the owner's manual, you can download it here:
http://www.chpower.com/webapp/wcs/s...51&langId=-1&catalogId=10001&findModel=wf2000

Hope this helps.

 

[Jake SS]

Hmmmm......!!!!

 

[Wozzaaah]

As fas as it running hot, the easiest thing you could do is plug it into a long extension cord, that would reduce the heat output.

Hope this helps.

Sorry Jimbob, no it doesn't. Running a welder on a long extension lead can result in too much volt-drop, it can cause the extension lead to overheat and could possibly damage the machine.
If running an extension lead it has to be of sufficient size to keep volt-drop to a minimum.
Not good advice at all I'm afraid .

 

[Jimbob]

I've done the extension cord thing, and it did reduce power. The extension got warm, but not terribly hot. If I weld anything thicker than sheet metal, I will always plug it directly into the 120 volt plug-in.
I do understand that too low of an AC voltage can hurt some transformers so this would have to be done with care.
A better and safer way to reduce heat might be to add a length of wire to the GROUND clamp. This temporary mod would be reversible if it provided un-satisfactory results. Reducing the load on the secondary side of a transformer won't hurt anything.
Definitely try the smaller .030" flux-core wire rather than the .035".

 

[micheljcardin]

I'm thinking of maybe creating a trigger that relates to the power and feed where I can tweek it on the fly; or maybe make it trickle with the use of a brushes on a shaft that I can also tweek. And sheet metal you can probably solder it overlapped prior to welding the edge after; I have seen a rolling edge bending tool lately that a person was using in order to work the tin and even self tapping screws could force the pieces to snug together if they are curved but overlapped isn't a bad idea though because after it's welded you can just hammer the weld flat and another way would be to add a load like a toaster that you control on and of with a peddle or what not; I haven't tried it yet but I had a ****ty experience with my first one that seemed to get snagged in the casing that the stigner draws the line. Cheers

 

[Pigeon_Droppings2]

If there's access you can clamp a copper plate behind the steel being welded....that will absorb the heat and prevent blow thro to an extent

Given how cheap inverters are I'd say you'd be better off with a cheap inverter welder...reliability and backup might be an issue but it might get the job done!

I was given a free buzz box...I spent many many hours trying to learn stick welding but it was impossible. In the end I opened up the box and it turned out the power handle wasn't actually connected to anything!