Weldernators

[rb70383]

Designing my truck I am not sure on a belt driven air compressor or a 12V one. Researching this I came across onboard welding using a spare alternator. The weldernator is just using an alt running wide open for welding. This got me to thinking that a spare alt could be mounted to the engine and used for welding or a spare alt if needed and the mounts would be so that the belt could be moved from one to the other as needed if the my alt died.

Havent seen it on here so figured I would ask.

 

[Cody1771]

its not just a alternator running wide open, it has a voltage regulator built into it, there are lots of rigsrunning dual alts for big electrical loads or as backup, if you want a welder it can be done pretty simply with 2 batteries wired to make 24 volts. as far as a compressor goes it all depends on what you have room for. i have seen people take AC pumps and turn them into compressors because most have a built in electric clutch and therefore can be controlled from the cab, but the new 12V ones from ARB or ViAir are really nice units and can inflate very quickly.

 

[Black Dog]

You can convert your a/c unit into an air compressor too. That would be kind of cool if you didn't mind not having a/c any more.

 

[Scoutn79]

If you have the room you can do both. I run a converted A/C compressor to run On Board Air...It never runs out like a power tank and puts electric units to shame with CFM....and is a cheap mod to boot. Simple designs can be put together for less than $100.00.
I also run a Delco 15Si alternator converted into a welder. The modifications required to convert the alt. to the welder do not harm it and I keep all of the parts taken out so I can put them back in and use it as a spare if the CS144 dies....or if someone elses alt dies. This too can be built for less than $100 with the biggest expense being your welding leads (GOOD jumper cables at least I use true welding leads I got from a rigger I use for free) I have done the battery welding before but the voltage can't be regulated like with the engine driven one...Mine runs voltage wide open so I control it by engine RPM. Taking batteries out to weld is a real PITA and what if you are alone OR you kill both batteries of your and your buddies truck?

Kind of hard to see in the picture but the OBA is next to the right battery with a small air filter and the alt on the left is the welder.
Darrell

 

[bob91yj]

I've been happy with my Redi Welder spool gun, it relies on two batteries as well. My quick fix for that (when I have the room) is two AGM motorcycle batteries pre wired in a marine/trailer battery box. Biggest advantage is it's portable between vehicles.

The owner of my race team has been known to use two batteries, some jumper cables, and the antenna off of the Ham radio as filler to weld a Jeep suspension mount back together. He stumbled across some folks broken in Moab a few years back, 15 miles from any where and they didn't have a clue on how to help themselves. I can't find the pic of him welding using 5 pairs of sunglasses stacked on his mug for eye protection (not recommended, but it worked).

 

[Black Dog]

I've seen coat hangers used as welding electrodes too. Its real dirty because there's no flux or gas shield but it works in a pinch.

 

[rb70383]

I have seen that pic somewhere with the 5 pairs of sunglasses. Dont know the sotry behind it though. LOL

I need AC, however the truck has a spot for an emissions air pump. Which I have ready arent good air pumps. So the spare alt was going there, along with a throttle level for voltage reg like stated. IIRC the doidoes need to be cahnge as well to non-avalanche style. I should have an old RV2 AC compressor that I was going to try to mount but found out about the weldernator. I could probably have both belt driven. hmmm Also the newer 12v compressors are nice and alot easier to install vs a belt driven ac compressor, and keep teh current ac.

Cody, not running the alt as a dual alt setup. The internal regulator is bypassed if the alt used has one. So the alt will just be mounted on the enigne unused until I need to weld or the main dies. I will then have an external reg mounted and ready to bypass the stock system. currently it is controlled by the pcm and seems to be a common failure on the earlier pcm controlled regulators. Its an 89 Dodge.

i read about using the chevy alts, not sure on the dodge ones, as I have a couple old 80's 120amp alts from an old ex-cop car Diplomat.

Lots of info from Google

Wanted first hand experince with them. Also read that using the wrong alt will kill it quickly. Hence the diode swap, but not sure if that fixes all the issues.

 

[UHAULER]

We run one of these welders on our work truck. It' nice because you don't use a throttle cable. It has a button on the stinger to raise the rpm's so you don't have to go back and forth between welding.


http://www.zena.net/

 

[sixbennetts]

My tgb11 is 24 volts, does this mean I can weld with it?

 

[Ozarker]

I'm not a very good welder but I know this can work, but I'd disconnect my batteries from my vehicle soI didn'y fry anything else. Having that spare alt. ready to go is a great setup.

 

[Scoutn79]

One thing about trail welding is you are typically ( at least on older vehicles) welding some fairly thick material suspension, frame and shock type components so the need to vary your welding heat is limited....practice at home welding similar thicknesses you are going to need to weld in the field and with the rod you plan to use...then just remember/write down what engine rpm you need for each. There isn't any jumping around trying to figure out what rpm you need when you need it.

After all the vehicle your welding might be in a bad position or the weather might not be so great so the quicker and safer you get the welding done the better off you are. The nice thing about stick welding is that it is more tolerant to dirty metal than wire welding is.

When we had to battery weld 2 batteries weren't enough and 3 were to much so the weld was too hot, but it worked and, as ugly as it is, hasn't needed to be redone in the last 10+ years.
Darrell