Welder
hardware
This was a sketchy project to create a stick welder out of microwave oven transformers.
I started by obtaining free microwaves off the side of the road and off of craigslist, then disassembling them and isolating the transformers.
I then cut the secondary winding and replaced it with 6 gauge wire with about 10 coils, this reduced the output voltage from ~2000V to 5-10V (one transformer was ~10.6V and the other was ~5.7V)
I did multiple tests, first with a single transformer, which yielded poor results, which prompted the upgrade to two transformers. This was still significantly under powered, as I learned later, but this project stopped there.
After rewiring the transformers, I hooked them up in series to get a higher voltage to get a longer spark; having a longer spark would allow me to have the stick further from the work piece which would prevent it sticking.
Testing again, the difference between a single transformer and two is stark (the first picture is with the single transformer, and the second is with two)
After testing connections, I began construction of a case to protect the circuitry, as well as adding a fan in parallel, and a control switch.
Eventually, everything ended up working as well as you'd expect, which is to say, not great, though I'm sure it was a combination of a terrible tool in the hands of an inexperienced user. I was able to use it for creating a crucible holder and forge, however, so I learned how welding works and got some practical experience and use from it.
I ended up buying a proper welder and have slowly been improving my skills.
Yes, I recognize I was attempting to weld on a galvanized plate and zinc plated rod while in a low ventilated area, I am aware of the health risks/consequences, and I no longer do that, and recommend nobody ever do that either.
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