How to Build a TIG Welder Water Cooler

The Tungsten Inert Gas (TIG) welder, with its telltale sign of a bright, white electrical arc, is made for continuous welding of special metals such as stainless steel and aluminum. The TIG welder can become very warm in the torch handle if there is not an ample supply of cooling water. For continuous welding, a constant supply of water is needed to keep the torch handle at a comfortable temperature. By following a basic procedure you can set up and build an inexpensive cooler apparatus to keep the torch head and your hand matching the performance of the welding unit.

Difficulty: Moderately Challenging

Instructions

Things You'll Need:

• 10- to 15-gallon open-top container (cooler basin)
• 3- to 5-gallon per minute (GPM) submersible water pump with 1/4-inch fittings
• 50 feet of ¼-inch clear plastic tubing
• 3 small hose clamps
• Screwdriver
• Razor knife
• Plywood cover to fit the top of the container
• 120 VAC wall outlet

1. Set the cooler basin next to the TIG welder location, and place the submersible pump inside. The closer the cooler is to the torch handle assembly and torch cord, the easier it will be to attach the water tubing along the entire length of the torch cord.

2. Remove the outer jacket covering of the torch cord to expose the gas tubing and the electrical conductor. Snap open the jacket and fully remove it to expose the two copper fittings on the lower end of the torch handle. These fittings will conduct the water into and out of the torch handle.

3. Unroll the ¼-inch tubing and attach one end to the fitting on the torch handle. Secure the tubing with a ¼-inch hose clamp and use the screwdriver to tighten. It does not matter which copper fitting the tubing is attached to, as the torch handle cooler makes a simple loop through the plastic handle.

4. Run the plastic tubing down the length of the torch cord until you reach the submersible pump inside the container. Cut the tubing to length with the pocketknife and secure the tube to the pump's output fitting with the hose clamp. This will complete the tubing for the feed water.

5. Attach the remaining tubing to the other copper fitting on the torch handle. This is the drain water that will run back into the cooler basin. Use the ¼-hose clamp to secure the drain tube to the torch fitting. Cut the tubing to length so it can sit inside and on the bottom of the cooler basin. If you have enough tubing, you can form a loop that will rest along the inside edges of the cooler basin.

6. Reapply the torch cord's cover, and fit the new tubing inside the covering.

7. Fill the cooler with fresh water, and cover the top with plywood to keep out any large debris. Plug the pump into the wall outlet and observe that water is draining from the drain tube in the bottom of the cooler.

Tips & Warnings

• Check the level of water in the cooler every day before operating the welder.
• Follow all manufacturer's instructions for operation and setup of the TIG welder.