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  1. O

    "Copper/nickel sandwich" buses for series connections

    You can make heavier leads but dont make them any longer than original. That makes inductive kickback stronger and max amps that welder can survive lower. Best place to get more power is battery. You did not say how much current you currently have when welding but you can go up to 1800-2000A...
  2. O

    "Copper/nickel sandwich" buses for series connections

    If that works fine for you then its fine I guess. If you want to get same result for less joules then you need to get amps up and time down so copper dont have time to soak up all the heat..
  3. O

    kWeld - "Next level" DIY battery spot welder

    Caps need cc/cv to not damage itself or input device. I quess you can rig something up with battery + something + caps but I see no advantage other than off the grid and posibly more portable. Lipo and 12v starter batteries can be used directly with welder. Depending how big/high end you go you...
  4. O

    "Copper/nickel sandwich" buses for series connections

    Sorry but I dont think you have any chance. If you have the materials then you can try and post results.. Anyway if you try 0.1mm nickel plated steel and 0.1mm copper there is a chance off somewhat decent welds but you have to try to figure that out.
  5. O

    kWeld - "Next level" DIY battery spot welder

    Yes sorry. Excuse my metric brain :oops:
  6. O

    kWeld - "Next level" DIY battery spot welder

    You can also try to keep battery voltage little lower. Thats big battery so it will still weld many times even when nearly "empty". Or use 8avg battery wires will also loose couple amps..
  7. O

    kWeld - "Next level" DIY battery spot welder

    Original cables are shorter than 1m but that is partly because when you connect lipo there is x ammount of wiring integrated to the lipo brick. Same for sla when you put your favorite connector + short cables with battery terminal clamps. And like said above having shorter wire is a lot better...
  8. O

    kWeld - "Next level" DIY battery spot welder

    Wire size chances resistance and therefore welding current depending your setup. Wire lenght chances how bad the inductive kickback from weld pulse is. Shorter wire is means less kickback. If wires are longer than original you need to chance the wire lenght value wich sets welders over current...
  9. O

    kWeld - "Next level" DIY battery spot welder

    Series unless you get overcurrent error. Then paralel and if thats no good then just 1. You also might have to get thinner copper or thinner steel strips if you are not able to get good welds. 0.2 copper is just so hard to weld. You need weld current close to kweld max current just to have chance..
  10. O

    kWeld - "Next level" DIY battery spot welder

    As you said. 1200A is plenty for nickel and nothing is enough for copper basicly :lol:. With nickel copper sandwich you probably get better results with more current. With 2nd battery paralel you may or may not go over current limit. Really no easy way to be sure before you try with your...
  11. O

    kWeld - "Next level" DIY battery spot welder

    Sounds like you have bad connection or dirty tips or something. Usually when I burn things my connection was bad and sparks fly. However kweld should have protection against that too. Cant remember the correct term for that but its adjustable. What kind of readings you get after good and bad...
  12. O

    kWeld - "Next level" DIY battery spot welder

    If you can get that 1600A up closer to 2000A you can probably use a lot less joules and get pulse time also down and not melt fuse. With copper pulse that long just heats the copper all around the weld and not just the spot weld.
  13. O

    kWeld - "Next level" DIY battery spot welder

    I first saw only one battery connected but at second look you have both paralel. 1000A seems little low for thouse batteries so that could be the issue. I have used 110Ah starter battery and it welds around 1500A so yea..
  14. O

    kWeld - "Next level" DIY battery spot welder

    0.2mm copper is so close to the limit what kweld can weld. With current close to 2000A it is barely possible atleast some cases. Also 0.2mm copper for 18650 cells is usually little bit overkill since 0.1mm or even nickel is enough for most cases. But please do post results of your work with...
  15. O

    kWeld - "Next level" DIY battery spot welder

    You can go to 100j but that might still not work since the reason why copper is so hard to weld is its ability to conduct the heat away from the weld spot. When you set more joules that basicly means longer pulse time and that means copper has longer time to spread the heat away so at some point...
  16. O

    kWeld - "Next level" DIY battery spot welder

    Smaller diameter wire would add resistance but that would get hot. Less cells on paralel or series will reduce current. Or just different battery if you have. Car starter or rc Lipo maybe :roll:
  17. O

    kWeld - "Next level" DIY battery spot welder

    Ok. I assumed that you were talking about the battery you use for the welding. Even weak welds may be ok when measurin ir or current but real issue can be how well it can handle bumps from riding. You really should figure out how to keep your wirelenght inside the spec. That likely can cause...
  18. O

    kWeld - "Next level" DIY battery spot welder

    Why even try to measure ir if you use the battery for kweld? Just use kweld to measure amps during weld pulse and that should be enough in my opinion. 1500-1999A if you want to try copper and if just nickel up to 0.2mm little less is enough. I would like to have over 1000A anyway.. If battery...
  19. O

    kWeld - "Next level" DIY battery spot welder

    Kweld has also software overcurrent and overtime limits. I have no idea what is wrong with his welder but something seems off. Hummina Shadeeba if possible you should post your calibration results and all the info that is shown after weld (time, current, joules, resistance). Also have you done...
  20. O

    kWeld - "Next level" DIY battery spot welder

    Around 50 joules with my 1500A battery. With copper amps matter a lot more because weld time should be as short as possible to make sure energy is used to weld and not just heating copper around the weld.. With nickel or steel on top method I have not tried yet but it should be better way to go..
  21. O

    kWeld - "Next level" DIY battery spot welder

    Hello. Someone can probably calculate how your capasitor bank behaves with kweld if you have datasheet for your caps. Or atleast ir value I think.. But I can only say that probably yes it can handle it. However if I had supercapasitorbank of unknown specs I would use adjustable cc/cv...
  22. O

    ”The barge” efoil build

    Its all good and fun untill lake freezes over :lol:
  23. O

    Spot Welding Copper Strips to 18650 Battery Cells

    I have not tried thicker than 0.2mm copper so 2mm must be totaly different beast to weld. Maybe if electrodes are placed on opposite sides (one against 2mm copper and another 0.15mm nickel side) it would be easier or even possible to weld :roll:.
  24. O

    kWeld - "Next level" DIY battery spot welder

    No problem. You might be able to use even 4th battery in paralel but that could be very close or over 1800A that is max recomended I think. I have not tested the nickel over copper method but 0.1 to 0.15mm nickel should be thick enough and cheaper and even easier to weld. Edit : After changes...
  25. O

    kWeld - "Next level" DIY battery spot welder

    90 joules sound like a lot to me. I think I used 50-60 just for 0.1mm copper. It is not very strong weld since the material is just too weak by itself. You should try thinner nickel and thicker copper. Also if you have more batteries you should try to ad one more paralel so weld current goes up...
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