Xrain wrote:Your using a MIG welder right?
If it feels like the wire keeps hitting the surface your welding and pushing the cup away it would be that your feeding too fast, or you are giving it enough power.
If the stuttering is it makes an arc and breaks it, then makes it again etc. etc.
Then my best guess would be it's not feeding properly, so either a wire has come loose and the feed motor intermittently gets powered, Or your line is too gunked up with crap (have you run aluminum wire through it at all?).
Also whenever your using a wire feed, try to keep the line as straight as possible sharp bends in it keeps the line from feeding properly. Lastly, try the tentioner on the feed wheel inside the welder, it could be it doesn't have enough tension, but be careful not to over-tighten it because you will flatten the wire and just make the problem worse.
If your using a stick welder, then I feel sorry for you, I had to weld a whole bunch of really thin stainless steel with a stick welder and it was a huge pain in the ass. If this is the case, make sure your ground-wire is still intact, and clean up the grounding clamp, next attach it to clean metal relatively close to where your welding (1-4 feet) If you are going with stick, what kind of rod are you using?
amberwolf wrote:I'm about ready to build a welder out of a motor controller running a small motor that drives a really heavily-wound motor (like the one out of a treadmill, perhaps, or a car alternator) as a generator, rectifying that, and running it to the electrodes. Then hook that into the HF feed mechanism that seems to work ok. THen I could use the motor controller to vary the current by varying the motor/generator speed, in theory. Better than having just a Hi and Lo setting like the HF welder has.
katou wrote:1) braze it instead. Incorporate laps etc to allow brazing
2) use battery from bike to weld with stick.
3) build bike from thicker steel to allow stickwelding more easily
And dude, getting all the fishmouths right, then having the welder wreck them? That is the WORST!!
amberwolf wrote:As for losing hope, well, I took a good look at the welder, and despite verifying contacts (and even recrimping and then soldering several high-current connections), it still just stutters much of the time. Too much to weld this frame with, cuz I just keep burning holes.
The only thing I haven't done, which I will once I get done feeding the dogs in a bit, is to bypass both the power switch and the thermal cutoff on the transformer, in case one of those has an internal problem causing high-resistance or something. Since it does it for both positions of the Hi/Lo rocker switch, I don't think that one is a problem, or it would likely only happen in Lo, as I have only used the Hi a very few times. If it comes down to it I'll bypass that one, too, in "permanent" Lo mode.
katou wrote:There must be custom bike builders in your area. If you could get them interested in what you are trying to do, they would probably accede to doing a weld or two for you, heck, any fabricator would do.
Xrain wrote:So it could certainty be your thermal cutoff, I've hit the duty cycle on welders before while TIG welding, and it didn't stutter it just shut the machine off, granted this was a miller, and not a Harbor Freight...
But it could just be that its malfunctioning, so definitely try to bypass it and see if that is the problem, but if it is that, becareful how much you weld as without that you could easily cause the welder to burst into flames.
But your bike is looking excellent!, and I cant wait to see it drive.
I'll try to pick my brain a bit more and see if I can think about anything else for your welder, if I do I'll let you know.
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