Thinnest thing you've ever TIGed...Showing off...

There was a thread like this over on WW and I was really bored today and decided to see if my Weldernator had enough finesse to handle this sort of thing. I would have tried to tackle a pop can but I only have DC- to play with. These blades are .021" thick. Filler wire was .035" ER70-S6. Was all I had.

Setup:
Blades were clamped to a large block of aluminum for a heat sink backing.
Max amps @ minimum setting. (Really have no idea the amount of current I was using.)
Foot Pedal: 1/2-2/3
Tungsten: 3/32" 2% Lanthanated
Argon: ~12-15CFH
I struck up the arc on the aluminum backer then moved over onto the blades. For my first attempt at welding razor blades I'm pretty happy with it. I know these are pretty thick blades, but I don't think I have enough amp control to do regular single edge blades.

http://i456.photobucket.com/albums/q...azorBlade4.jpg

http://i456.photobucket.com/albums/q...azorBlade1.jpg

Brad, I think it's safe to say you've earned show-off rights by a) making a DIY welder that works at all, b) making your own torch to run off it, and c) welding such fine material with it.

Speaking of pop cans and welding thin material, did anyone else notice the background of photo #10 in Jakeru's post the other day. It appears he has invented the 24 ounce double ended beer can.

Thanks for the compliments DaveO. I've put quite a bit of work into this home-built setup. It just amazes me how well it works every single time I use it. I honestly didn't expect to have enough amperage control to be able to weld razor blades together, especially with a scratch-start. Everything I've ever read about "weldernators" was that they were very crude devices, that they were only good enough to make emergency welds to get your 4x4 home when you've broken something out on the trail. When I built mine I set out to change this way of thinking and I think I've finally gotten there with this setup. Hell if I had some High-Amp IGBTs I could build a switching stage on the output and get square-wave A/C out of the thing, but that's a little much I think. At least it is giving me a way to learn/practice TIGing while I'm raising funds for a PowerTig 250EX and a PowerPlasma 60. After I get those two machines I'm thinking about trying to get some welding/cutting work on the side so I can make the machines pay for themselves. Anyways, enough of my ramblings. Let's see everybody else showing off their TIGing skills, I'm sure they're much better than mine since I only have about 1-1/2 hours under my belt with a TIG.
I didn't see the picture you're talking about. Are you saying he butt welded the centers of the cans together? That would take some serious skill and serious amp control right there.

I agree on the show of rights. I think I saw his torch here on the forum somewhere (part PVC).

I might have an old WP18 around with a burnt hose or missing connector, will look and if I do and shipping is not a lot, will send it to you if you want it. :)

I hope Brad is in the contest, we need to work on getting him a welder. :D

Weld looks good, I see you drifted a little in the middle, but they should hold. What are you powering the alternator with (gas electric?)? Gas would make it portable for sure.

The problem I see with Jake's invention, once one is empty, you have to hold it or it will want to tip on you being top heavy.

Looks good. I investigated the Alternator welder a few years back (never built one, just internet searching). At the time there was someone who made a fairly elaborate control for the output (DC only) which included pulse I believe.

Now on to thinner razor blades Brad.

BTW, I like the clarification in your location.

Just East of "Smicksburg"

I'm using an old 1.5HP 220V Westing House motor from my air compressor. I'm pretty sure I saw that one you were talking about. I also seen one where the guy built some kind of electronic contraption onto the output to make it CV so he could mig weld with it. I'll see if I can't dig up some thinner ones and see if I can't get them stuck together. Sportbike, you're close on the location, we are a little bit south as well, I live very close to Plumville. I put that in there because telling people you live in "Home" tends to be a little bit confusing sometimes. =)

Quote:

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Originally Posted by blasphemy000

...since I only have about 1-1/2 hours under my belt with a TIG.

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I forgot about this part- this should be part "D" of my post from yesterday. Built your welder, built your torch, welded razor blades, and oh yeah by the way, no formal TIG training. You've aced the final exam but you never attended class!

Thanks dude. I think for only having the internet and myself to learn from, I think I'm doing pretty good. Especially considering my equipment. I just can't wait until I get a real machine, I'm sure I can get some work for it. I already made up fliers and everything.

Quote:

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Originally Posted by everlastsupport

I agree on the show of rights. I think I saw his torch here on the forum somewhere (part PVC).

I might have an old WP18 around with a burnt hose or missing connector, will look and if I do and shipping is not a lot, will send it to you if you want it. :)

I hope Brad is in the contest, we need to work on getting him a welder. :D

Weld looks good, I see you drifted a little in the middle, but they should hold. What are you powering the alternator with (gas electric?)? Gas would make it portable for sure.

The problem I see with Jake's invention, once one is empty, you have to hold it or it will want to tip on you being top heavy.

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You are correct about the torch being partly of PVC. Yeah, definitely let me know about that torch, if the cable or something is damnaged I'm sure I could figure something out for it. Or if its just missing a connector that's not really a big deal either. My cables don't exactly hook up like a regular welder does. Haha.

I think its safe to say youre an amateur welder with more to learn. Looks like you got the basics down pat.

Quote:

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Originally Posted by SDunlop909

I think its safe to say youre an amateur welder with more to learn. Looks like you got the basics down pat.

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Now add a real welder and some time. He'll be fine. This should be in the chat lounge.

You must admire in some respects, he was playing around. Learned something. People here got into it. No way I would use that on a job. The time he put into it, if he put that in a welding project, that focus will get him far and probably make him some money.

Thanks guys. I would agree that I have lots and lots and lots more to learn, in all flavors of welding, but especially TIG. I'm sure once I get my hands on a real machine I'll be able to further improve on my skill and technique. And no, I don't use my weldernator on any "jobs." I did use it to weld up the dashboard for my off-road buggy I'm building, but other than that it's just not suited for any real work, it's just nice to practice and play with. I think with some good equipment(and much more practice) I could make a little bit of cash on the side doing some welding for people. I made $200 over the summer fabricating & welding up some "wheel guards" for the corners of a mower deck on a mid-sized kubota tractor. The guy kept catching the wheels on stuff and ripping them off the deck. I ground out all the original welds, welded them back up, then built a guard around each to deflect things away from the small casters. He mowed all summer with it, said he even smashed them into things multiple times, and they're still holding up good. Was my first real welding "job."

The point of this thread kinda went sideways though. I wanted other people to post up pictures of things they have welded that we're really thin, really difficult, or just generally impressive. I know my weld wasn't really any of these, but I was wanting to see other's examples of such, especially if it was done with an Everlast machine.

What type of current did you get with the pedal setting?

Any more cool pictures of thin material?