Learning to 120 V AC 90amp Flux Core Weld

[bob58o]

HF 90 amp (120v) AC gassless flux core welder

I upgraded the grounding clamp, changed the wire, replaced the MIG nozzle, replaced the tip.

This is my first attempt at welding.

Tried first on min setting and didn't like it. Tried turning up wire speed and still didn't like it. Switching to Max made a big difference. After a half hour, I felt much better about MY chances at being able to do REAL welding with this machine in the future.

The last thing almost looks like a "weld"!

 

[chancer]

Cool. What welder do you have?
HF of course
"thats where you get everything"
Lots of guys have really good luck with those.
The only thing is Get "lincoln" wire at Home depot. The HF stuff is junk.

 

[bob58o]

I already got the Lincoln wire, next phase includes a big capacitor and bridge rectifier. Turn this puppy into a DC Electrode Negative (the proper way to use flux core apparently)!

---------- Post added at 05:18 PM ---------- Previous post was at 05:13 PM ----------

Cool. What welder do you have?
HF of course
"thats where you get everything"
Lots of guys have really good luck with those.
The only thing is Get "lincoln" wire at Home depot. The HF stuff is junk.

Not proud of my collection of Chicago Electric, Pittsburgh, and US General tools, but the only way I could afford going from no tools to any kind of collection was Harbor Freight. I basically had no tools when I started this project. Now if I could only find a 1/4" drive, 1/4" 12 pt socket to fit my 1/4" HF in-lb torque wrench.

---------- Post added at 05:37 PM ---------- Previous post was at 05:18 PM ----------

I was thinking about slapping a 2.5HP "Walmart Made in USA" sticker on there but Ryafor never got back to me. lol

There's a void to fill.

Apparently, the pigeons carrying my DIYGK stickers are not ballsy enough to Fly into the Chicago Burbs. Or may have been cross-fire victims?

 

[mckutzy]

Typically it should have a pole near the feeder rollers where the gun is plugged into, where you can switch the polarity...
I'm kinda surprised its AC only. AC in for power I get... ... Are you sure it is...

The thing with these machines.. They need clean metal...
Weld/tack.... Brush(if they are close together, but none the less the cleaner the better. ).... Continue welding/tacking.

 

[bob58o]

120 v AC in. Also AC out

 

[chancer]

Hey, Harbor Freight Tools are great for us Home Shop guys.
Some of them just would not hold up to a tradesman using them all day every day.
Others some of the Grinders tradesman use all day for years and Love.

 

[bob58o]

Typically it should have a pole near the feeder rollers where the gun is plugged into, where you can switch the polarity...
I'm kinda surprised its AC only. AC in for power I get... ... Are you sure it is...

The thing with these machines.. They need clean metal...
Weld/tack.... Brush(if they are close together, but none the less the cleaner the better. ).... Continue welding/tacking.

https://m.youtube.com/playlist?list=PLd_DTtq1stJJ4C0qlUnxqBvrfLXLKDyYr
Need to fit capacitor and bridge rectifier to make it smoothish DC. Not very easy to find, unless taking from a better welder or EBay

That's why it was 90 bucks! They removed the gas, the cap, and the rectifier. Add the cap and rectifier (another 60-75 bucks).... It's much more like a $300 welder (but still no gas).

I want a bridge rectifier with a large heat sink that I can mount on the case

 

[bob58o]

Hey, Harbor Freight Tools are great for us Home Shop guys.
Some of them just would not hold up to a tradesman using them all day every day.
Others some of the Grinders tradesman use all day for years and Love.

Here's a little confession... concerning Harbor Freight.

Remember, this is my first time working with any kind of engine.

After watching a bunch of how to mod the Predator videos. I tried it. I got the kit, removed the gov, removed the low oil sensor, advanced the flywheel, cut wires, sealed up holes.....

When it wouldn't start, I started researching "Why won't my engine start?"

Found out all it needs is 3 things... Gas, Spark, and Compression.

Checked the Carb and Fuel Line... It was good.

Took out the spark plug, reconnected it, laid it against the block, and tuned the engine over.... I had a spark.

Started researching "How to check compression."
Went back to HF and bought a compression tester. I found out that I didn't have compression.

What I did not realize, is that when I was removing the low oil sensor and governor components and the lifters and push rods fell out... that a simple slide back into hole wouldn't work. I never opened the valve cover.

I, instead, removed all the parts I had just installed and tried to make it look stock again. I drained the oil and gas, put it back in the box, and brought it back to HF. I told them it had no compression. They gave me a new one with no hassles.

I did the whole thing again. This time I made sure push rods were set in the rockers and I also set the valve lash after.
Worked fine.

I was too embarrassed to ask what was wrong on the forum and figured a little practice was good anyway.

If they didn't exchange it, I was going to have to ask for help on the forum and accept my 20 "LASHES" from the Poboy for being stuuuuupppidddd.

 

[landuse]

You did what all diy guys do, so don't sweat it. I also watched loads of youtube vids and did lots of research

 

[bob58o]

I'll share bad with good. This is bad for removing head bolts. Broke on 2nd bolt.

Returning it right meow.

 

[chancer]

A few years back My Dad bought an electric pressure washer from Wal mart.
He was on vacation in Pennsylvania and wanted to wash his 81 yr old Moms concrete walks.
The Pressure washer worked good and he got the Job done.

He returned the Pressure washer to Walmart and told them he got it for his Dad,
but His Dad did not like it.

The thing is His Dad had died 5 yrs prior!!

 

[supermanotorious]

well since HF will no longer honor 20% coupons on Predator engines, I have no truck with exchanging something because of my mistake

 

[supermanotorious]

I cant believe I hadn't heard about the DC conversion until now. But this is why we hang out around here isn't it! So I ordered one for my brother in law and myself. They should arrive today and I can't wait to test some welds with it. Yesterday I made a machine to increase hand strength. I copied THIS design for a friend who is a WAL professional arm wrestler. I made the machine with the 90amp HF machine and HF wire. I wanted to be reminded of how terrible it is stock, prior to the upgrade.

 

[chancer]

Tell us more about this machine?

 

[supermanotorious]

LOL

you hang weights from the ring near the end of the "handle"

you can repetitiously squeeze the short and long handles together

OR

what my gentle giant friend does, is load it up with weights, uses one arm to raise the long handle to the short one with a ton of weight, then holds the handles together as long as he can with one hand

 

[bob58o]

well since HF will no longer honor 20% coupons on Predator engines, I have no truck with exchanging something because of my mistake

I found an online coupon or got one in my email. It was going for $120, I got it for $100. They gave me a non Hemi after I asked for 60363. I saw they had the Hemi #60363, so I returned before I left the store. I modded it, and didn't check pushrods.... So I returned it again. So technically I'm on my third Predator, 2nd Hemi. Lol but I only started one. Lol

---------- Post added at 02:35 PM ---------- Previous post was at 02:32 PM ----------

I cant believe I hadn't heard about the DC conversion until now. But this is why we hang out around here isn't it! So I ordered one for my brother in law and myself. They should arrive today and I can't wait to test some welds with it. Yesterday I made a machine to increase hand strength. I copied THIS design for a friend who is a WAL professional arm wrestler. I made the machine with the 90amp HF machine and HF wire. I wanted to be reminded of how terrible it is stock, prior to the upgrade.

You are doing the DC conversion???
Will you start a thread on it so we can see????

 

[Poboy kartman]

You did what all diy guys do, so don't sweat it. I also watched loads of youtube vids and did lots of research

And can still screw up a scrambled egg!!!!!

 

[bob58o]

You'd be surprised what I can screw.... UP.... Screw Up..... You'd be be surprised what I can screw up! Lol

---------- Post added at 03:23 PM ---------- Previous post was at 03:20 PM ----------

Speaking of screw up. If you got time check out my intake port and let me know what you think.

 

[supermanotorious]

I don't really want to start a new thread, so here it is. All in all it was pretty straight forward. I didn't drill the best holes for the terminals to pass through and I mixed up the d@mn panels so now they're on opposite sides. I picked up 8ga ring terminals from Ace Hardware. Here are some welds done with- believe it or not- crappy Harbor Freight wire! This mod is 100% necessary.

 

[bob58o]

I don't really want to start a new thread, so here it is. All in all it was pretty straight forward. I didn't drill the best holes for the terminals to pass through and I mixed up the d@mn panels so now they're on opposite sides. I picked up 8ga ring terminals from Ace Hardware. Here are some welds done with- believe it or not- crappy Harbor Freight wire! This mod is 100% necessary.

Very cool!
Did you just use the bridge rectifier, or a capacitor too?