Wire the alternator. Cut a piece of wire to run between the positive battery post and the alternator's "Field" terminal. Cut the wire with wire cutters. Using wire strippers, strip the end off of each end of the wire. Use wire crimpers to secure a terminal end onto each end of the wire. Cut a piece of 4 gauge wire to use as a welding lead. This should be 10 to 12 feet long. Strip both ends with a wire stripper. Connect one end of the wire to the "Output" terminal bolt of the alternator. Tighten it with a wrench. Connect the other end to the welding electrode holder. Tighten the connection with a wrench.
There are many types of welders on the market today. They have uses ranging from light-metal auto body repair to full-on heavy steel fabrication. Most people who do welding at home do not require or need a professional type of welding system. They are able to get by with a small home unit. But what about those people whose passion takes them off-roading? These people need an emergency welder that they can operate in the field to make repairs to their vehicles. Luckily, the answer is right under their hood. A welder can be constructed using a car alternator for power.
Things You'll Need
- Ford alternator
- Wire cutter
- Wire stripper
- Wire crimper
- Wire terminals
- Welding electrode holder
- Welding rod
- Locking pliers
- Jumper cables
Connect the power wire. Connect one end of the wire you cut to length in Step 1 to the "Field" post of the alternator. Tighten the bolt with a wrench. Connect the opposite end of the wire to the positive battery post. Tighten this with a wrench.
Weld the part. Insert a welding rod into the electrode holder. Place a jumper cable end on the frame of the vehicle the welder is on. Place the other end of the jumper cable onto the piece that is to be welded. This will ground the piece. With the engine running, strike an arc with the welding rod and make your weld.
Tips & Warnings
- If you have trouble with the welding rod sticking, have a friend press the throttle pedal down on the welder's engine. Increase the RPMs and you will have no problem with the rod sticking.
- Do not weld without eye protection. You can injure your eyes from the bright light of the welding.
- Photo Credit mig welder image by Jake Hellbach from Fotolia.com
How to Build Your Own Tig Welder
How to Build Your Own Tig Welder. ... How to Make Alternator Welders. There are many types of welders on the market...
How to Use a Car Alternator to Make a Generator
The car alternator's role is to produce electricity for your vehicle. ... You can have this done professionally if you're not proficient...
How to Build a Wind Generator with a Car Alternator
In some instances, welding the alternator directly to the rotating wheel makes sense, ... DIY Wind Generator Plans; Homemade Turbines & Windmills;
How to Build a Welder
How to Make a Portable Welder With Two 12-Volt Batteries; TIG Welder Tips; ... How to Make Alternator Welders. There are many...
How to Weld Metal Without a Welder
How to Weld With an ARC Welder; Comments. Related Ads. Watch Video Worn Out Headlights? ... How to Make Alternator Welders; ehow.com....
DC Generator Vs. Alternator
How to Test Your Car Alternator for Power. When a car battery isn't providing enough power to start a car, people often...
Basic Parts of a Welding Machine
Basic Parts of a Welding Machine. Welding machines are used to permanently connect metal pieces with heat generated from electrical energy. ......