Did you DIY your water cooling system?

[DaveO]

I'm thinking about how I'd assemble a water cooling system for a TIG welder, and looking for tips and tricks.

I just picked up a small submersible 110v water pump, and it seems like that thing in a 5 gallon bucket should do the trick. I'm also thinking about using a heat exchanger of some type, maybe from a dehumidifier.

I've read other posts talking about using a automotive water pump- what else have you used or improvised to make yours work?

Thanks!

[WILD BILL]

I'm currently researching parts for one.

when I get it all sorted out I'll post the results.

So far it's looking like I'm using these parts,

http://www.grainger.com/Grainger/LIT...ner-Pump-2P018

http://cgi.ebay.com/ws/eBayISAPI.dll...=STRK:MEWNX:IT

http://cgi.ebay.com/6-FT-PC-Computer...86883749933140

With just under 2 gallons and the limited welding I do I doubt I'll need a heat exchanger but if it turns out I do I may pick up a small rad from

http://www.dangerden.com/store/black...-radiator.html

Still gotta figure out a possible fan

I'd like to pack it all in one of these

http://www.hammondmfg.com/1453.htm

But so far coming up with one cheap has been a challenge

Then it should just be a matter of plumbing from the hardware store

[DiabolicZ]

I thought about how I'm going to do mine for about 5 seconds last night. I am heavy into aquariums, so I have extra pumps laying around. I am going to rig one of those up in line with something along the lines of an Oil cooler for a car or a fuel cooler. Something aluminum with fins basically.

I would just have the power head (pump) pulling water from the cooler and pushing it to the torch. That way the pump never sees hot water.

[DiabolicZ]

I'm currently researching parts for one.

when I get it all sorted out I'll post the results.

So far it's looking like I'm using these parts,

http://www.grainger.com/Grainger/LIT...ner-Pump-2P018

http://cgi.ebay.com/ws/eBayISAPI.dll...=STRK:MEWNX:IT

http://cgi.ebay.com/6-FT-PC-Computer...86883749933140

With just under 2 gallons and the limited welding I do I doubt I'll need a heat exchanger but if it turns out I do I may pick up a small rad from

http://www.dangerden.com/store/black...-radiator.html

Still gotta figure out a possible fan

I'd like to pack it all in one of these

http://www.hammondmfg.com/1453.htm

But so far coming up with one cheap has been a challenge

Then it should just be a matter of plumbing from the hardware store

Wow, you are going all out! I mean that is cool and all but... you know... why?

Milk jug $1,000,000,000
$10 aquarium powerhead
line and fittings from the hardware store $20 max.
some kind of chiller $20

So a maximum of $1,000,000,050

[WILD BILL]

I thought about the aquarium power heads but couldn't get a concise answer as to weather they would be up to the task. Some say go for it and others say not enough pressure. Most use a procon pump but I could never find the "deals" they say they got.

I got the cord so I didn't have to worry about Making sur I plugged in the cooler before I started.

I want all this relativly compact so that it fits on the bottom shelf of my HF cart and still leaves room for the pedal.

[Wrenchtamer]

I'm thinking about how I'd assemble a water cooling system for a TIG welder, and looking for tips and tricks.

I just picked up a small submersible 110v water pump, and it seems like that thing in a 5 gallon bucket should do the trick. I'm also thinking about using a heat exchanger of some type, maybe from a dehumidifier.

I've read other posts talking about using a automotive water pump- what else have you used or improvised to make yours work?

Thanks!

Not a water pump. I can't think of any that would be suitable for the task. I think you mean fuel pump

[sportbike]

Might be able to use a pump like this:
http://www.surpluscenter.com/item.as...&catname=water

Not sure what the flow and pressure drop requirements are for a torch.

Surplus center always seems to have "useful" items for things like this.

[DaveO]

Wild Bill, I'm gonna click those links to get a feel for your setup. And Wrenchtamer you're right, I meant fuel pumps.

These web sites have a "pumps" section, but they also have a lot of other cool stuff.
www.sciplus.com American Science and Surplus
www.herbach.com Herbach & Rademann

[WILD BILL]

One of the other reason I'm going with this pump is it only draws about 1.2 amps.

They also make one that is 220 V that draws .6 amps.

[Zoomie]

Wild bill,
Awesome! It looks like you've really been doing quite a bit of research. I actually enjoy tracking down all the stuff via the internet. My only issue undertaking projects like this is changing channels if my original idea isn't going to hold water. I really think the fan driven by the pump motor is a pretty elegant solution on some of the factory units. I thought maybe doing an independent electric fan with a thermstatically controlled switch, that way you only have to hear the pump run up til the fan switches on due to enough temp variation.

[angular]

Not sure what the flow and pressure drop requirements are for a torch.

50 PSI (max) and 1 quart per minute seem to be the widely accepted figures. The actual PSI required to push 1 quart/min though the torch is going to vary depending on the cables & torch used.

[WILD BILL]

Like you're really gonna hear the pump or fan over the welder

I have been researching intensly since I burnt up the power lead on my WP 20 welding with no cooler


Did a quick serch for a 110 v fan that would fit that small rad.

http://shop.ebay.com/?_from=R40&_trk...All-Categories

[angular]

http://www.grainger.com/Grainger/LIT...ner-Pump-2P018

http://cgi.ebay.com/ws/eBayISAPI.dll...=STRK:MEWNX:IT

I'd like to pack it all in one of these

http://www.hammondmfg.com/1453.htm

That pump is 110V and the outlet on most Everlast welders (as far as I know) is 220V. Also the max pressure rating is 35 PSI. It seems "geared" more for volume than pressure.

I like that steel enclosure. Any idea what those cost? I need one for my DIY cooler.

Bradley

[WILD BILL]

They do make a 230V version of that pump

http://cgi.ebay.com/Little-Giant-35-...item2561892227

I Was just going to split the phase in the cable so that I didn't have to modify the welder and possibly void my warranty.

Still waiting to see if that Granger pump is in stock. If not I'll probably get the one I just listed.

I'm using 12.5' torch and wont likely ever be welding with it more than a couple feet over the pump so I figure the pressure to raise the water through for my needs wont be to bad.

I will however test it at full rise to test the max I can lift the torch while still getting proper flow of coolant.

Sorry, I have yet to find any retail pricing on that enclosure.

[angular]

Looks like it's $116 at Digikey. Costs add up fast. If I bought that enclosure, I'd be pushing $400 for my DIY cooler. Conclusion: the Everlast W300 is a pretty nice unit for the money.

[DaveO]

Angular, that"s a very clean setup, nicely done. Where is that little radiator from? And is that quart jug in back the reservoir?

[WILD BILL]

Looks like it's $116 at Digikey.

I may just leave it exposed or build my own box.

[Zoomie]

Wild Bill,
Your shop must be pretty noisy or you are always welding in AC! My old man's Coolmate predecessor sounds like a freight train with bad bearings. It is so noisy it is distracting. It's turned off when changing set ups and when the torch is not going to be taxed too much. To each his own I guess. Loud noises aren't usually the killer of hearing, its the continuous stuff that can get ya, and my leads are only 10-12 feet.

[DiabolicZ]

Looks like it's $116 at Digikey. Costs add up fast. If I bought that enclosure, I'd be pushing $400 for my DIY cooler. Conclusion: the Everlast W300 is a pretty nice unit for the money.

+1^

That is what I was getting at with these super intricate custom coolers. Cost's add up quick, just buy the unit from everlast if you want a decent cooler, and it will match your machine. Or buy one somewhere else... whatever.

I usually tell my wife. "If I can make it for cheaper than I can buy it... I will."

[angular]

Angular, that"s a very clean setup, nicely done. Where is that little radiator from? And is that quart jug in back the reservoir?

Here's some info on my set up...

Heat exchanger (radiator):

http://www.summitracing.com/parts/DER-13300/

Procon carbonator pump (part # 111A100F11AA) and it's rated at 100 GPH (@ 100 PSI) or about 1.67 GPM.

http://cgi.ebay.com/ws/eBayISAPI.dll...m=230582068842

The internal bypass valve on the pump doesn't seem to go low enough (without completely unthreading), so I'm using an adjustable relief valve to bleed off excess pressure.

http://www.mcmaster.com/#8088k14

That relief valve is actually pretty nice for the money and easy to adjust by hand, so I'm glad I got it. Excess flow from the pump gets routed through the heat exchanger, so would I imagine around 1.5 gallons per minute are flowing through it at all times.

Pump motor:

http://www.grainger.com/Grainger/MAR...p-Motors-5XB85

Reservoir:

http://www.suremarineservice.com/001-395.aspx

Reservoir is maybe 2 quarts. Worst part is not the volume it holds but the the barb fittings being pretty small so the return flow really "jets" into the tank and tends to foam things up. Overall I would say this cooler is massive overkill for my use!

EDIT: Let me just reiterate this very important point...

The Everlast W300 cooler is a very nice unit for the money and it would be a serious challenge to build something as polished or "turn key" as that for $400. I really hesitate to encourage people to go down the path I went because it's a slippery slope and not really cheaper in the end (if time invested counts for anything). If you're a hardcore DIY type and enjoy this sort of thing, that's cool, but the only real advantage to my setup at this point is a pressure gauge and adjustable pressure regulator.