Spot Welder recommendations

dirtdad · Jun 9, 2008

Can anyone recommend an affordable home spot welder? DIY ideas are OK, but not sure I am up to making something like that.

For battery boxes, I like the idea of spot welding aluminum. I have tried sheet metal screws, but you have to make room for the heads and grind off the tops for thin sheet metal. I don't think the final product is very strong, and a spot welded box could be more compact.

TylerDurden · Jun 9, 2008

dirtdad said:
For battery boxes, I like the idea of spot welding aluminum. I have tried sheet metal screws, but you have to make room for the heads and grind off the tops for thin sheet metal. I don't think the final product is very strong, and a spot welded box could be more compact.

I suggest pop-rivets.

dirtdad · Jun 9, 2008

Something like this, maybe?

http://www.arizonatools.com/tools/riveters/detail/AST1426/?utm_source=googlebase&utm_medium=organic&utm_campaign=productfeeds

TylerDurden · Jun 9, 2008

dirtdad said:
Something like this, maybe? http://www.arizonatools.com/tools/riveters/detail/AST1426/?utm_source=googlebase&utm_medium=organic&utm_campaign=productfeeds

More like this:

http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=40690

If you plan making a quantity:

http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=93458

fechter · Jun 9, 2008

They had a bunch of these things on eBay for around $150.
Just do a search for "spot welder"

I don't know how well they work, but for thin aluminum it might be OK.

Drunkskunk · Jun 9, 2008

IRRC, Aluminum takes some specalized spot welders. they need like 3 times more current, and a pulse cycle 3 times as fast.

TylerDurden · Jun 9, 2008

The spot welders above and at HF weigh about 25 lbs.

dogman dan · Jun 9, 2008

Tylers right, rivet it. If you have large airport nearby an A and P mechanic would have the stuff to rivet with aircraft rivets. Or a local homebuilder. Or buy the tool from guys who sell to aircraft homebuilders. I don't know if the tool is cheap or not, but most likely not. But they make nice flush rivets.

lawsonuw · Jun 9, 2008

http://www.aircraftspruce.com/ should have everything you'd ever want.

For thin stuff seams can also be rolled and hemmed and all kinds of other esoteric things. Also 3M and others make structural adhesives and tapes for gluing up sheet metal. Or a nearby radiator shop could help with a vacuum brazing job.

My two watt hours,
Marty

Spot Welder recommendations

dirtdad

1 kW

TylerDurden

100 GW

dirtdad

1 kW

TylerDurden

100 GW

fechter

Administrator

Drunkskunk

100 GW

TylerDurden

100 GW

dogman dan

1 PW

lawsonuw

1 kW

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