Hi, Gang: I'm trying to home-brew a spot welder for 26ga sheet steel and not having very good luck. I started with a huge transformer (11" x 11" x
14") with the core in the shape of a hollow square and four coils (two on one side and two on the opposite side). The secondary coils are wired in parallel and the primarys are set up with four terminals, equally spaced, with copper shunt bars so you can arrange them to be either series or parallel. There are NO data plates, the only writing on it is "Birdsell Welder". The core has a movable center piece and is marked with rod sizes, the further you withdraw the center piece the bigger the rod you can use. I removed the movable center piece completely, wired the primarys in series, and wound a new secondary from #4 stranded copper, five turns around one side of the core. This gives me 120v in and 5v out. My ampmeter only goes to 100 and it pegs instantly under load. I made tongs and tips from Brass (The only thing I had). This thing makes very poor welds. Ten seconds (Way too long) with two layers of 26ga steel are just barely stuck together and break apart easily, leaving just a small pimple at the contact point.Where did I go wrong?
Any insight appreciated
Roger in Vegas Worlds Greatest Impulse Buyer