How to Build a Stick Welder

Now you can make a stick welder instead of buying one.

Whether in an emergency situation or just wanting to build a cheap yet effective stick arc welder, you can do so with some supplies you probably already have around the garage. This technique allows you to quickly put together a simple DC (direct current) arc welder that uses batteries as a power supply. Using AC power outlets from your home or garage can result in serious injury as the amount of power available at them is considerably higher and would still need to be inverted to DC anyway.

Things You'll Need

• 3 car batteries
• Heavy electrical wiring (6 gauge)
• Jumper cables (heavy duty)
• Welding rod stick

Instructions

1. Place the three car batteries near your work area on a stable work surface or the floor. Arrange them so that negative terminal on one is next to the positive terminal of the other, as close together as possible.

2. Wire the three batteries in series. On the first battery, connect a length of electrical cabling, as short as possible, between its positive terminal and the negative terminal on the second battery. Connect a second length of wire, also as short as possible, between the positive terminal on the second battery with the negative terminal on the third battery.

3. Connect one of the two black clamps on the jumper cables to the negative terminal on the first battery. Connect the red clamp (at the same end of the cables as the black clamp you just connected) to the positive terminal on the third battery. Make sure that the black and red clamps at the other end of the cables are not in contact with each other.

4. Clamp the free black clamp on the opposite end from the batteries to a bare metal surface of the piece of metal you wish to weld.

5. Clamp an arc welding rod in the teeth of the free red clamp of the jumper cables. Strike a weld by scratching the tip of the welding rod against the metal you wish to weld. When the tip of the welding rod touches the metal, it will complete the electric circuit, melting the welding rod. This will quickly discharge the batteries, which will need to be recharged with a battery trickle charger slowly.

Tips & Warnings

• Always wear appropriate face and eye protection when welding and working with steel.

References

• WheeliePete: Guide to 3 Car Battery Arc Welding
• Mother Earth News: Build a $20 Portable DC Arc Welder
• LCool: Emergency Welding Using Automotive Batteries