Resistance-No Resistance wire welder

[jmarkus]

So after my LM2577 board was a dud, I went to the local CVS and asked the film department if they had any spent cameras with a flash, sure enough they had a big recycle bucket and gave me one for $0 (ok, I bought a coke too).

Removed the board from camera along and pulled any non essential components off the pcb. Added the two black leads for momentary switch. Added red and black leads from capacitor that attach to #8-32 bolts. Hot glue into box, attach the leads and switch to top of box. End result came out pretty good, with the bolt studs I have more than enough room to put my welding alligator clips plus leads or clips from my dmm. The little bits of plastic tubing on the ends are just to prevent my wife from shocking herself accidentally and throwing my project in the trash By pulsing the switch you can actually control the voltage charge pretty easily. I was targeting 165v when I took the picture here. I found that I could pretty consistently come within +/-10v of targeted voltage. FWIW, 165v seems perfect for welding 32g nickel to 32g kanthal.View attachment 168388View attachment 168389View attachment 168390View attachment 168391View attachment 168392

haha...so f'in amazing. even simpler without the on off switch and leds. very very simple, clean and easy mate...excellent.

 

[kwalka]

I dont even know what to say. I was in one of the orig threads when they first found the Greek vid. There are lots of Ody clones hitting the market and these need to be made avail to the masses.

It's threads like this that make me proud to be a member of this community.

BTW, we are supposed to use the Everclear to clean attys? How does the atty get back out of my stomach?

We will cal this subscribed!

 

[gdeal]

So let me get this straight. I need to drive over the bridge to NJ to get everclear. Stop at a CVS on the way to get a used disposable camera. Come home and then try not to electrocute myself?

Is the everclear for before or after I attempt this?

 

[UA72Riddle]

Ever clear before....to ease the pain....

Ever clear after....to celebrate...

How's that?

 

[JazzyTech]

Everclear and High Voltage....

Sounds like the beginning of a really bad AC/DC tune...

 

[asdaq]

I get mine back around Franklin County VA but they don't call it "EverClear".

Might this be from a guy named Tickle? I remember going from Seattle to Montana to get Everclear, now it is much closer.

 

[cyclotron]

Might this be from a guy named Tickle? I remember going from Seattle to Montana to get Everclear, now it is much closer.

LOL, Tickle. I grew up in Climax VA and lived there as an adult before moving to Hampton Roads VA. Actually, Climax VA is in Pittsylvania County and not Franklin County. I enjoyed my wasted youth....

 

[breaktru]

Spark'in and Everclear don't mix well.
Don't go a exhal'in while spark'in
especially to close to the face area

There's a reason they put up signs of no smoking at the gas pumps.

 

[TBinAZ]

Ok, so here is what I'm bangin around right now. I'm no electronics expert, but would you want to regulate the incoming voltage to the cap for the desired output, or the output voltage itself from the cap? I'm thinking the input, but appreciate any insight.

 

[dsy5]

Ok, so here is what I'm bangin around right now. I'm no electronics expert, but would you want to regulate the incoming voltage to the cap for the desired output, or the output voltage itself from the cap? I'm thinking the input, but appreciate any insight.

That would be the best way to do it, but I don't know whether it is a DC input voltage, without seeing one in person or at least a schematic. Controlling the output to the cap could be possible, though. Since it really doesn't need to be a regulated voltage, a simple voltage divider with a potentiometer to vary the voltage might work.

I don't like the idea of charging it to a certain value by removing the press on the charge button - you have to use a DMM and be ready to stop - maybe not that big of a deal, just sayin'. Don't have one yet to tinker with.

 

[breaktru]

Ok, so here is what I'm bangin around right now. I'm no electronics expert, but would you want to regulate the incoming voltage to the cap for the desired output, or the output voltage itself from the cap? I'm thinking the input, but appreciate any insight.

With your Voltmeter connected, tap the fire button and you will slowly increase the charge of the capacitor to a desired voltage.
I found that 32 gauge works good with 165-170VDC. It works great controlling output voltage. Each tap increments the charge.

 

[breaktru]

That would be the best way to do it, but I don't know whether it is a DC input voltage, without seeing one in person or at least a schematic. Controlling the output to the cap could be possible, though. Since it really doesn't need to be a regulated voltage, a simple voltage divider with a potentiometer to vary the voltage might work.

you guys are thinking too hard about a simple way with just a tap of the charge button.

 

[TBinAZ]

My thought is that you really wouldn't have to think about it, just push for 4 secs no matter what. Just me thinking too hard... LOL

you guys are thinking too hard about a simple way with just a tap of the charge button.

 

[breaktru]

Adjusting Capacitor Charge Voltage:

 

[TBinAZ]

So where in the mix are you adding the resistance to bring the voltage down? Output? Sorry, I'm kind of a dolt when it comes to this stuff.

Adjusting Capacitor Charge Voltage:

 

[gsa]

So where in the mix are you adding the resistance to bring the voltage down? Output? Sorry, I'm kind of a dolt when it comes to this stuff.

He is just discharging the cap in a controlled way. + to ground with the resistor in the middle. He has the resistor on the hot side and then just touch the - lead to the other end of it.

I made 20 wires last night and this morning, I didn't feel the need to ever discharge like this, it is pretty easy to hit your voltage with a little practice.

 

[gsa]

I don't like the idea of charging it to a certain value by removing the press on the charge button - you have to use a DMM and be ready to stop - maybe not that big of a deal, just sayin'. Don't have one yet to tinker with.

It's really super easy. Plus the electronics are pretty much free, so you can buy a dedicated dmm for this and still be way under the $100 Greek one.

 

[gsa]

Adjusting Capacitor Charge Voltage:

I agree, the most important factor here is definitely getting a good connection and short lead on the resistance wire (nr can be longer). Good idea on the washers, I made up some different leads today using this type of flat jaw copper clip that I had in the treasure chest:

 

[mre777]

Adjusting Capacitor Charge Voltage:

Nice idea with the washers man, I' gona have to give that a try

 

[Lutonant]

Great work guys, going to try this