So I been given a 130 amp flux core welder and I plan on converting it to real mig/mag but the out put is AC and ready it need to be dc iv ordered a 150 amp single phase rectifier and planned on adding some capacitors to help smooth out the dc.

There a a few other modifications I'm planning on making like adding a new mig torch that adds gas for shielding thing it's called euro torch mb15.

Also adding a supply for the wire driver as I'm told this drops when welding.

And cutting off the 13 amp plug top and replacing with a 32 amp blue plug but running on a 16 amp braker

The question is dose this sound like a worthwhile conversion and are there any other modifications people can suggest thanks and any better ways of smoothing out the dc
Thanks

 

Use a Bridge Rectifier or 4 stud Diodes, ideally 25 to 50A rated to get better DC, most welders on this don't have any capacitors used on the output as the current is high.

 

So I been given a 130 amp flux core welder and I plan on converting it to real mig/mag but the out put is AC and ready it need to be dc iv ordered a 150 amp single phase rectifier and planned on adding some capacitors to help smooth out the dc.

Being a dedicated flux core welder it is AC. But just adding a rectifier won't make it a Mig welder, how are you going to add the valve for the gas? And the timer circuit for that valve? And then you say the wire feeder is not working too, is this really something you want to throw money at? Most flux core only welders are at the bottom of the pile when it comes to reliability and dependability.

 

I think you misunderstood me wire feeder is fine but it drops when the arc is firing, causing voltage drop to the motor, so I'm adding a transformer run off a relay so it has a dedicated supply.

With the gas you can get a conversion kit new torch with gas supply tubing added to the torch so it will be a hole new torch with gas, the gas solenoid will be triggered by a relay via the torch trigger.

with the timer not sure why you need that guess you could add one so gas would activate before the arc but your only talking a few seconds.

And as cost wise I'm only really paying for the new torch which will cost about £28 and my own time

Thanks

 

Here's the torch upgrade

 

I think capacitors would defeat the high frequency arc start.

 

with duty cycle 50A@60% 120A@10% I think it will be pretty much useless for anything.

 

with duty cycle 50A@60% 120A@10% I think it will be pretty much useless for anything.

Well there's always someone wanting to put a smile on your face in there

 

It will certainly be an interesting project, but I do suggest that you find a way to examine some other welders that are in the same class as what you are hoping to create. I have used a wire-feed type MIG welder and it was great because I am not at all good at stick welding. But duty cycle is a real issue, since things do get really hot fairly quick. I also suggest taking a look at the service manual for a welder similar to what you propose. I am not an expert on welders, but I do know about educating ones self before spending money and effort.
AND, Good Luck!

 

Iv been looking about at other people that have carried out the same modifications and a lot of people have had grate out comes, but I am concerned about the duty cycle but I'm save that till later after these modifications are sorted.

At the moment I'm looking for the best way to smooth the dc, most people have use capacitors around 45000 uf but looking at the welders of the same spec use inductor coils but I'm not overly sure on how to work out what type I'll need or make

 

Iv been looking about at other people that have carried out the same modifications and a lot of people have had grate out comes, but I am concerned about the duty cycle but I'm save that till later after these modifications are sorted.

At the moment I'm looking for the best way to smooth the dc, most people have use capacitors around 45000 uf but looking at the welders of the same spec use inductor coils but I'm not overly sure on how to work out what type I'll need or make

It is not clear as to why it needs filtering, BUT you can also add a large series coil and a diode to keep the current flowing, and no capacitor. The series coil will be to store energy and release it through the load during that time when the rectified output voltage drops. The diode is across the DC source, normally biased off, but as the rectified voltage drops the diode allows current supplied by the magnetic field in the choke to continue to flow. A whole lot like a choke input filter circuit.

 

The reason behind wanting a cleaner dc is because the arc will be more stable and cause less splatter and give a better weld.

I must admit I'm not totally clued up on working out what type of coil I'll need iv got some heavy enough cable to use.

What is the best way to work out the type of configuration I would need for the welder?

Any advice would be much appreciated thanks

 

The reason behind wanting a cleaner dc is because the arc will be more stable and cause less splatter and give a better weld.

I have a commercial type welder a Millermatic 35 one that at the time was the go to welder in a lot of industry. If you are under the assumption you will get away from spatter with Mig, your fooling yourself. If you want no splatter bite the bullet and get a Tig. Tig is both spatter free and if done correctly stronger than Mig. But weld strength still comes down to the weldor not the welder. For your reference on the difference of the words - https://wikidiff.com/weldor/welder

 

I have a commercial type welder a Millermatic 35 one that at the time was the go to welder in a lot of industry. If you are under the assumption you will get away from spatter with Mig, your fooling yourself. If you want no splatter bite the bullet and get a Tig. Tig is both spatter free and if done correctly stronger than Mig. But weld strength still comes down to the weldor not the welder. For your reference on the difference of the words - https://wikidiff.com/weldor/welder

From what I have seen, good Tig welding is a high skill operation, while even I can produce an adequate Mig weld with a wire feed gas shielded machine. So just as you say, there is a lot more to it than just the machine.

 

From what I have seen, good Tig welding is a high skill operation, while even I can produce an adequate Mig weld with a wire feed gas shielded machine.

A good looking Mig weld bead isn't always necessarily a strong weld.

 

A good looking Mig weld bead isn't always necessarily a strong weld.

My welds always survived other people's hammer tests, and even today they have not failed. I did read the books on what makes a good weld, and I understood them.

 

My welds always survived other people's hammer tests, and even today they have not failed. I did read the books on what makes a good weld, and I understood them.

And I have ground welds apart, to deconstruct an item, that had a perfect looking weld visible and no bead or penetration at the root of the joint.

 

As I was teaching myself how to weld, not all of mine were good welds.