Everyone who drives off-road knows the fear of a cracked bracket miles from the nearest town. This build tackles exactly that problem: an emergency stick welding setup that runs on two vehicle batteries and jumper cables, small enough to carry along for repairs away from any shop.
The layout is straightforward. Two 12-volt lead-acid batteries are disconnected from vehicle electrical systems, then linked in series with a short 4-gauge battery cable joining the positive post of one to the negative of the other, forming a 24-volt circuit. A jumper cable from the remaining negative post feeds locking pliers that hold the electrode, while the red cable from the remaining positive post serves as the work clamp, making this a direct current electrode negative arrangement. An open-end wrench tightens the battery connection nuts, and a welding helmet plus a fire extinguisher round out the equipment list.
For the demonstration, the positive lead was clamped to two stacked metal brake rotors, and the arc fused them with visible weld beads. The slag was then chipped and wire-brushed off, and the finished joints were held up to the camera along with the surface test passes. When done properly, the method draws roughly 150 amps, which is modest compared to a typical 8000lb winch under full load approaching 500 amps.
The maker is upfront about limits: this works well in emergencies but should not replace a primary shop welder. Carrying welding rods is described as insurance against a long walk home. One open question remains, since the maker is not certain which electrode was used, only believing it was 1/8 inch 6011, though 6011 or 7018 are said to handle most trail repairs well.
Project by Matt Verley. Watch it on their YouTube channel: