On-board Welder (OBW)

LiftedAWDAstro · Post by **LiftedAWDAstro** » Sat Sep 30, 2006 7:45 pm

Well after seeing some write-ups on converting an alternator to a welder, I figured I would give it a try! I used a CS-130 Delco alternator from a 93-94 Astro. I got the welder from Bill with the engine accessory bracket attached to it. I will keep a running cost total as well. I was originally thinking of using a 2nd serpentine belt and cran pulley but have since changed my plans. I spent many hours trying to figure out where to mount the welder and figured on the 96 and newer vans there is room just to the left of the A/C compressor and I could utilize the factory mount for the A/C delete idler pulley. The welder will run off the stock serpentine setup although it will require a new, longer belt. I checked the Dayco website and there a a lot of belt length choices so that will be the easy part!

Costs:
1. Alternator - free
2. Steel for brackets - free
3. welder/grinder consumables - est. $5.00 for entire project

Theory: In order to make an alternator into a welder you will need unregulated voltage output. To do this I removed the regulator from the alternator. To do this, you will need to pull the alternator completely apart. You will have to un-solder the stator 3 phase power leads from the rectifier bridge. Once this is done the alternator will completely separate. You then unsolder the regulator circuit board assembly and solder a lead (14 gauge wire) onto the positive side of the field armature at the brush. The other brush will go to ground (batt -). Once this is done you just put it all back together without the regulator section.

Tests: We did this at work with limited time so we don't have any hard core tests to show. Here is what we do have: With 12 vdc on the field, you will draw just over 4 amps through the field windings. You then spin the welder over. Since we only had quick access to an 18 volt drill which only spins at 1600 rpm's, we were able to get around 19 vdc out of the welder. Normal operating rpm will be in the 6,000 to 7500 rpm range so voltage should be plenty...plus the welder should be capable of 105 amps in theory!

Now for a few pics:

That is all for tonight!

jakepatch · Post by **jakepatch** » Sat Sep 30, 2006 7:58 pm

I'll be curious to see how this one plays out. Keep up the details and pics!
Of course now I gotta figure out how to fit a V8, air compressor, AND welder in there! ](*,)

astrozam · Post by **astrozam** » Sat Sep 30, 2006 8:19 pm

You big TEASE , LOL ( cool factor rating of 10 )

SafariRob · Post by **SafariRob** » Sun Oct 01, 2006 3:19 am

Wooo-hooo! How cool is this? =D>
Looking forward to hearing more about this one!

LiftedAWDAstro · Post by **LiftedAWDAstro** » Sun Oct 01, 2006 3:59 am

Well here are more pics of the install...enjoy!

These are the only 2 pics that show the alternator mods. We did it at work and couldn't take pics.

LiftedAWDAstro · Post by **LiftedAWDAstro** » Sun Oct 01, 2006 4:03 am

More pics...

That's it for now. I will be running the welding leads from the welder to a mount someplace and have a set of welding leads made up so all I need to do is put 12 volts to the field coil and then plug the welding leads into the stingers. I will also need to get a throttle control so I can set the throttle at between 2000 and 3000 rpm's.

SafariRob · Post by **SafariRob** » Sun Oct 01, 2006 4:18 am

Any idea of how the engine RPM is going to vary when welding?

LiftedAWDAstro · Post by **LiftedAWDAstro** » Sun Oct 01, 2006 4:27 am

Good question! I don't have an answer for it yet either. I am guessing that it will vary some but with the rev's up it won't be much of an issue. Even if it varies some it really won't matter because this welder is basically going to be used for trail repairs and possible remote welding repairs.

9dawgs · Post by **9dawgs** » Wed Oct 18, 2006 11:01 am

Wow, it must be nice to fab up something so easily! I think you are my new hero! Haha. Nice job. I just got through looking at the solid axle swap. Very impressive! $\:D/$

trybe13 · Post by **trybe13** » Wed Oct 18, 2006 12:00 pm

Very impressive Dean, as usual! Man, why can't I find someone around here with your skills that's into vans that would be willing to teach me?!?!?!?!

Someone · Post by **Someone** » Wed Oct 18, 2006 2:14 pm

you may be able to get an electronic PTO for the van... I have one from a ford F-350 that plugs into the OBDII port,... I know they are expensive from Ford but I bought two of them slightly used for $60 bucks for the pair at a swap meet... my friend has one in his tow truck and it works great, select your RPM and hit go!

Rileysowner · Post by **Rileysowner** » Wed Oct 18, 2006 8:29 pm

I'm with Zam on this one, cool factor of 10. I am looking forward to finding out how well it works and seeing it as well. =D>

LiftedAWDAstro · Post by **LiftedAWDAstro** » Thu Oct 19, 2006 4:12 am

This project has sort of stalled for the time being. I have other work to do on the SPB before snow flies. If it fits at all, it will be a very tight fit. I guess that is the problem with fabbing parts when the vehicle is 200 miles away! Thanks for all the kind words. $\:D/$

peter · Post by **peter** » Sat Oct 21, 2006 5:12 am

"IF" it fits? You mean to tell me you're not even sure it'll fit? Gotta hand it to you, you have courage...
PS: The brackets look awesome. I know what kinda work is involved in making up your set-up. Kudos!

Fire Cakes · Post by **Fire Cakes** » Sat Oct 21, 2006 5:27 am

peter wrote:"IF" it fits? You mean to tell me you're not even sure it'll fit?

Peter,
Of course IT always fits. $\:D/$

However the problem with the OBW is that he fabbed something up to go into the SPB using the engine that was sitting in the garage out in the wide open. Now that he needs to stuff it under the hood of the SPB there just might not be enough room. As he said that is the problem with having a vehicle in PA when you want to work on it. #-o

Chevy & GMC Vans

Chevy & GMC Vans

On-board Welder (OBW)

On-board Welder (OBW)