Modify 90 amp flux core to DCEN

[Jfive]

Not sure if anyone has thought or has done this, but the last time I had one of these welders I had planned on doing the conversion but hadn't done it when I traded it off for a turbo.

Purchased a 33000uf 50vdc cap and a 100amp 1200v Bridge rectifier. Have lots of crimps connectors and wire so hope to mod and share my results when the parts arrive. Should have a DCEN welder in a week!

Might try to have it so it can be done DCEP to try adding argon/co2 for a test at running er70s2/4/6.

https://m.youtube.com/watch?v=NoYN4vx1WU8

 

[supermanotorious]

http://www.diygokarts.com/vb/showthread.php?t=32519

http://www.diygokarts.com/vb/showpost.php?p=402540&postcount=19

 

[Jfive]

Did you add a capacitor too, or just the rectifier?

 

[supermanotorious]

haven't done the cap yet, it's a little pricey

 

[Jfive]

I searched for an hour and found one on ebay 18.99 shipped finally. Not too bad. Paid 12.99 shipped for rectifier. I'll have 95.00 into the welder when done with new tips and .030 Lincoln wire. Lol.
http://m.ebay.com/itm/Mallory-CGS30...r-Audio-Amp-/272149918462?txnId=1692120571017

 

[supermanotorious]

I'd get the cap at that price, your link isn't working though, what's the title of it?

 

[Jfive]

Fixed it cut the end off. Stupid phones

---------- Post added at 03:25 PM ---------- Previous post was at 03:15 PM ----------

Kinda expensive but I've thought about adding one of these. Might try and find one local at Napa or something. I think I bought one at Napa for my solenoid hub in my truck. But this would be mounted up top and allow one to switch polaritys without opening up the case every time.
http://m.ebay.com/itm/Dual-Power-Distribution-Block-3-8-1-Per-Quantity-/251405255562?nav=SEARCH

 

[supermanotorious]

https://amzn.com/B005S436Z4

http://www.ebay.com/itm/1-pc-Mallor...206109?hash=item1e8994245d:g:5DUAAOxyUgtTPG-S

 

[Jfive]

Goes to show why amazon is only good sometimes. I usally just use eBay.

 

[supermanotorious]

I dunno if they're exactly the same though 75V vs 10V ???

 

[Jfive]

Started to work on it today. Small mod, not even sure if its needed but did it anyways.
https://www.youtube.com/watch?v=Xr7wpjm9-qo

 

[supermanotorious]

Fixed it cut the end off. Stupid phones

---------- Post added at 03:25 PM ---------- Previous post was at 03:15 PM ----------

Kinda expensive but I've thought about adding one of these. Might try and find one local at Napa or something. I think I bought one at Napa for my solenoid hub in my truck. But this would be mounted up top and allow one to switch polaritys without opening up the case every time.
http://m.ebay.com/itm/Dual-Power-Distribution-Block-3-8-1-Per-Quantity-/251405255562?nav=SEARCH

why would you want to change polarity on that machine?

 

[Jfive]

Seen where a guy drilled a hole in the copper nozzle, added a tube(refrigerator tubing) and added co2/argon. Which uses the opposite of flux core. So you'd have a true mig (gmaw) welder. Just ideas.

 

[Jfive]

Parts arrived so started the conversion.

 

[mckutzy]

Is this an AC only machine..... And you want it Dc?

 

[bob58o]

Is this an AC only machine..... And you want it Dc?

Yes flux core should be DC electrode negative.
The cheap HF versions leaves out the Rectifier and Capacitor

 

[mckutzy]

Ahh.. That part was left out in the original description.

 

[Jfive]

Finished! Took it outside and plugged it in. Fan worked. Then pulled the trigger. Welder worked. Didn't do a comparison from the AC but we all know its bad so, I think it works good. What a pain hooking it up as all the wires are stiff and I clipped the gun wire too close to the connection and found it was aluminum wire. After the butt connector was copper, so hindsite I would have left the connector and spliced at the copper. Cost break down.

37.50 welder parking lot no warranty pallet find.
12.99 100 amp 1200v bridge rectifier
18.99 30000 50v cap
2.40+4.00 copper terminals
Wire free from ford ranger wire harness.
Shrink wrap free. Have a ton purchased in mystery box at garage sale.
15.99 1 lb Lincoln .030 wire
5.40 .030 tips(Hobart not the same thread)
8x32 by 1/2 screws washers and nuts and 5mmx30mm and washer and nuts. 2.00

Total 99.47 so close to original sale price!

 

[supermanotorious]

tell me you saw my recent thread and you plan on ordering a higher amperage rectifier before you fry that one!

 

[Jfive]

I did but the wire feed on mine went out so I need to replace that too. Need to find one on ebay.