Simple spool mod (0.7kg - 5kg)

[Tiggy_dorset]

Here is a simple mod for fitting a 5kg spool of wire to a small/narrow spindle found on most hobby machines.

Get an empty spool of 0.7kg wire and cut it in half.


Please note that the empty diameters can vary with different manufacturers. The last spool I bought from Weldequip (Parweld) is the perfect size to fit snuggly inside the 5kg spools. I have another old spool with a smaller diameter and will not work for this mod.


I had to cut a small ammount from the centre of modified spool to allow a little more thread for the tensioner nut, but a simple task.


There you have it....works for me

 

[Sub-arc]

Clever mod there

 

[Tiggy_dorset]

Clever mod there

Thanks. Dont ask me though, why I keep old empty spools around

 

[Fazerruss]

Thanks. Dont ask me though, why I keep old empty spools around

The reason is in your first post. You never know when what looks to be useless crap becomes usefull. For that reason I have a garage full of crap!

 

[penfold]

The reason is in your first post. You never know when what looks to be useless crap becomes usefull. For that reason I have a garage full of crap!

It's not useless crap, it's stuff that will come in handy! I have a length of brass box section salvaged from a dead radar; I have no idea what 12mm x 25mm x 1mm brass might be used for(other than a radar waveguide obviously), but I have even less idea where I might get such a thing for less than a king's ransom if I suddenly need it; that's my story and I'm sticking to it!

 

[aametalmaster]

Nice fix. I have some spools with 2 different sizes of centers too. I too have 5 garages full of good stuff...Bob

 

[Geodawg]

Interesting tip tiggy_dorset, can I ask you a question, is that welder a sealey 150 by any chance, if it is, did you do the euro conversion?

 

[BrokenBiker]

i tried making an adaptor for my mig when i converted it to gas, but the 5kg spool wont fit in the machine

 

[rich r]

I once saw a small mig welder converted to use the big spools by having an empty small spool in the normal place, and the big spool mounted on a bar out the back of the machine. The wire passed in through a hole in the back, wrapped round the small spool four or five times, then out into the feeder as normal. The small spool just acted as a pulley to pull the wire from the big spool outside. The whole thing resembled a film projector with it's big reel out the back on top I suspect the small spool may have had it's surface roughened to improve grip, but I guess as long as the wire's flexible enough it'd pull it round just fine. I have to say I never actually saw the chap weld anything with it, so it may have been a failed project...

 

[BrokenBiker]

I once saw a small mig welder converted to use the big spools by having an empty small spool in the normal place, and the big spool mounted on a bar out the back of the machine. The wire passed in through a hole in the back, wrapped round the small spool four or five times, then out into the feeder as normal. The small spool just acted as a pulley to pull the wire from the big spool outside. The whole thing resembled a film projector with it's big reel out the back on top I suspect the small spool may have had it's surface roughened to improve grip, but I guess as long as the wire's flexible enough it'd pull it round just fine. I have to say I never actually saw the chap weld anything with it, so it may have been a failed project...

the small spool doesn't need to have any grip, it is just acting as a tensioner, the wire feed motor does all the pulling

 

[Tiggy_dorset]

Interesting tip tiggy_dorset, can I ask you a question, is that welder a sealey 150 by any chance, if it is, did you do the euro conversion?

Yep it is a Sealey. Yep I did the conversion. What do you want to know?

 

[Geodawg]

Yep it is a Sealey. Yep I did the conversion. What do you want to know?

is it straight forward to do? where did you did you source your parts from? my torch sprung a leak which I've fixed for now using some resin, a replacement torch is coming in at 67.50 + Vat so if I could do the conversion it would work out cheaper in the long run.

 

[Tiggy_dorset]

is it straight forward to do? where did you did you source your parts from? my torch sprung a leak which I've fixed for now using some resin, a replacement torch is coming in at 67.50 + Vat so if I could do the conversion it would work out cheaper in the long run.

Its easy enough if you know where to connect the wires to. Im just off to the bank for an hour, when I get back I sort some information for you.

 

[rich r]

the small spool doesn't need to have any grip, it is just acting as a tensioner, the wire feed motor does all the pulling

That's a very good point. Duh.

 

[Geodawg]

Its easy enough if you know where to connect the wires to. Im just off to the bank for an hour, when I get back I sort some information for you.

Cheers mate, its much appreciated.

 

[Tiggy_dorset]

This is an old thread I posted regarding the location of the wires to the solenoid:
http://www.mig-welding.co.uk/forum/threads/euro-conversion-gas-solenoid.29352/

You should be able to see where I mounted the solenoid and where to take the feeds from.
I bought the euro connector from ebay. Lots of choice on there, probably all much of a muchness to be honest. I think I bought the parweld torch from Weldequip.

When you are ready to install it, I will be happy to walk you through it. It might be a good excuse to write up a proper clear guide to installing the conversion to the Sealey machine as I have seen it come up on here several times.

Give us a shout if you need any assistance.

 

[Geodawg]

This is an old thread I posted regarding the location of the wires to the solenoid:
http://www.mig-welding.co.uk/forum/threads/euro-conversion-gas-solenoid.29352/

You should be able to see where I mounted the solenoid and where to take the feeds from.
I bought the euro connector from ebay. Lots of choice on there, probably all much of a muchness to be honest. I think I bought the parweld torch from Weldequip.

When you are ready to install it, I will be happy to walk you through it. It might be a good excuse to write up a proper clear guide to installing the conversion to the Sealey machine as I have seen it come up on here several times.

Give us a shout if you need any assistance.

Nice one mate,hope to have funds after the 24th to buy the bits and will give you a shout...

 

[Geodawg]

Tiggy_dorset, I bought a full kit from the bay of fleas for a decent price, which came with what looks like good concise instructions. I'm going to try and fit it on Sunday so might need to pick your brain if it goes Pete Tong

 

[Tiggy_dorset]

Tiggy_dorset, I bought a full kit from the bay of fleas for a decent price, which came with what looks like good concise instructions. I'm going to try and fit it on Sunday so might need to pick your brain if it goes Pete Tong

no problem mate. Good luck

 

[Kent]

I once saw a small mig welder converted to use the big spools by having an empty small spool in the normal place, and the big spool mounted on a bar out the back of the machine. The wire passed in through a hole in the back, wrapped round the small spool four or five times, then out into the feeder as normal. The small spool just acted as a pulley to pull the wire from the big spool outside. The whole thing resembled a film projector with it's big reel out the back on top I suspect the small spool may have had it's surface roughened to improve grip, but I guess as long as the wire's flexible enough it'd pull it round just fine. I have to say I never actually saw the chap weld anything with it, so it may have been a failed project...

That sounds like a good modification, I have some doubt about some spindles being up to long term use of a heavier / larger spool. Recently looking at the CEA mig and this might have the above mod done at time of manufacture as the spool is housed at the rear ( I am going to test one shortly not been inside one yet) . An 18ga steel cover aint rocket science if you have a roller and are modifying your own.
Yes I like over-specification