kWeld - "Next level" DIY battery spot welder

Batteries, Chargers, and Battery Management Systems.
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The Lightning Stalker
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Re: kWeld - "Next level" DIY battery spot welder

Post by The Lightning Stalker » Jan 24, 2018 9:41 am

I'm in the market for ultracaps. Those Skels look good but they come in 10 packs and are weld only. I would need another welder to weld the ultracaps for my welder.

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Re: kWeld - "Next level" DIY battery spot welder

Post by spinningmagnets » Jan 26, 2018 10:58 pm

If anyone is having difficulty finding a small quantity of copper rod in 1/4-inch__0.25-inch diameter (roughly 6mm), I have purchased several feet, and can sell it by the inch, plus postage.

My local hardware store stocks solid copper wire in 8ga and 4ga as grounding wire for large junction boxes. This 6mm had to be ordered, and is considered 2ga.

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Re: kWeld - "Next level" DIY battery spot welder

Post by The Lightning Stalker » Jan 27, 2018 9:34 am

I don't know if these are new or if I just didn't notice them, but Thunder Power has some 120C stuff right now.
http://www.thunderpowerrc.com/CAR_BATTERIES/Reaper
The specs on these are getting pretty insane now.

Are there any plans for pulse arc capabilities on the kWeld? Of course it would need the proper solenoid tungsten holder. I'm thinking it could be useful for welding ultracaps etc.

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Re: kWeld - "Next level" DIY battery spot welder

Post by fechter » Jan 27, 2018 8:18 pm

Pulse arc is interesting. I did some experiments using a non-contact electrode and high voltage starter. I've never tried using a solenoid but it might work.
"One test is worth a thousand opinions"

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Re: kWeld - "Next level" DIY battery spot welder

Post by tatus1969 » Feb 01, 2018 5:38 am

The Lightning Stalker wrote:
Jan 27, 2018 9:34 am
I don't know if these are new or if I just didn't notice them, but Thunder Power has some 120C stuff right now.
http://www.thunderpowerrc.com/CAR_BATTERIES/Reaper
The specs on these are getting pretty insane now.

Are there any plans for pulse arc capabilities on the kWeld? Of course it would need the proper solenoid tungsten holder. I'm thinking it could be useful for welding ultracaps etc.
The "4800mAh 2-Cell/2S 7.4V Reaper 120C LiPo, Shorty" sounds really promising, they state 1152A max burst discharge. But can someone tell them that Deans/EC3/EC5/Traxxas/XT60 connectors are all hopelessly underrated for a battery that is rated for 576A continuous?
Resistance is futile - We Are The Watt.

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Re: kWeld - "Next level" DIY battery spot welder

Post by tatus1969 » Feb 01, 2018 5:40 am

fechter wrote:
Jan 27, 2018 8:18 pm
Pulse arc is interesting. I did some experiments using a non-contact electrode and high voltage starter. I've never tried using a solenoid but it might work.
I want to make pulse arc welding experiments with kWeld, as I think that this is well in reach. Maybe it just needs a higher battery voltage.
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Re: kWeld - "Next level" DIY battery spot welder

Post by tatus1969 » Feb 03, 2018 9:53 am

I have received the first batch of laser-cut housing parts for kWeld. Here is a picture of the first build, they will be available in my shop soon. These are much more affordable than 3D printed housings (unless you have a printer yourself), so I stopped the development of those.
kWeld-lasercut-housing.jpg
kWeld-lasercut-housing.jpg (127.22 KiB) Viewed 318 times
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Re: kWeld - "Next level" DIY battery spot welder

Post by andrew.box » Feb 03, 2018 12:10 pm

Wow, nice project. If you end up selling boards or kits please say so here. I bet we could get a number of people who'd reserve a board and parts. Also try the DIY power wall forums, those folks love spot welders.

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Re: kWeld - "Next level" DIY battery spot welder

Post by tatus1969 » Feb 04, 2018 5:43 am

andrew.box wrote:
Feb 03, 2018 12:10 pm
Wow, nice project. If you end up selling boards or kits please say so here. I bet we could get a number of people who'd reserve a board and parts. Also try the DIY power wall forums, those folks love spot welders.
I actually sell them: www.keenlab.de
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Re: kWeld - "Next level" DIY battery spot welder

Post by andrew.box » Feb 05, 2018 11:04 am

Cool, thanks! I'm currently wasting all my money on a Volt module based battery backup portable inverter project, but I may want to pick one of these up eventually. They look like great quality little spot welders and price is reasonable.

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Re: kWeld - "Next level" DIY battery spot welder

Post by okashira » Feb 12, 2018 3:55 pm

I just ordered one for some testing. :-)
How soon will it ship?
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Re: kWeld - "Next level" DIY battery spot welder

Post by tatus1969 » Feb 13, 2018 6:42 am

okashira wrote:
Feb 12, 2018 3:55 pm
I just ordered one for some testing. :-)
How soon will it ship?
Shipping is planned in week 9, but I am not sure if I can keep that because I have trouble with foreign customs at my board assembly service location. I will keep you updated.

Cheers
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Re: kWeld - "Next level" DIY battery spot welder

Post by bigbore » Feb 13, 2018 3:11 pm

I'm almost ready to turn my Kweld on for the first time. These are the massive 4AWG cables with 10mm diameter brass electrode holders. The electrodes I'm going to try for the first time are made with 3mm copper rode.

Image
Image

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Re: kWeld - "Next level" DIY battery spot welder

Post by spinningmagnets » Feb 13, 2018 5:59 pm

Those electrodes look good!

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