Battery welding

[Syncro]

I know this has been talked about before, but I have a simple question that I need a quick answer to. I have a short welding job (just a few 1-2" tacks) on the ranch where there is no power, can I hook two 12v car batteries in series and make it work? My thought was to attach my AC welders cables to the battery posts, use 1/8" rod and make a few quick welds with 24V DC. Has anybody actually done this? Don't want to blow up a lead acid battery.

 

[BB_TX]

Go to google and type in battery welding. You will get a bunch of hits that will tell you how to do it. I have never tried it. Good luck.

 

[Syncro]

Why didn't I think of that. Yup, there were a lot of good sources and pictures found on a Google search. I guess its a proven thing to do, but I gather that three 12v batteries are necessary and that the + is used as the ground. Makes sense as elect flows from - to +.

Anyways, thanks, sometimes the obvious is not so obvious /forums/images/graemlins/laugh.gif

 

[BB_TX]

I would guess it is similar to using a standard arc welder. DC+ gives deeper penetration, DC- gives less penetration but faster rod deposit. /forums/images/graemlins/confused.gif
Here is some good <font color="blue"> welding info </font> if you have never seen it.

 

[newlife]

I have done it a bunch of times. 36 volts work better, the rod will stick less.

 

[Casco1]

I've seen McGyver do it several times, instead of a wlding rod I think he uses a quarter.

 

[Buzz_Sawyer]

Works VERY well!
I believe as stated, that minimum of 36v is needed. it works much better.
Do series connect, above all MAKE SURE connections use short jumpers (1 foot)and very clean and tight connections.....if the connections arc could blow ya up or destroy post terminals.
also keep the leads longer so as to keep hot sparks away from hydrogen gas comming of battery.
/forums/images/graemlins/grin.gif

 

[RonMar]

Yes, 3 batteries is prefered for stick welding but if it is thin metal(less than 1/4") you can get away with 2 by using a smaller rod(1/16-3/32). There was a company a few years back that marketed a portable MIG welder. It was able to get away with 2 batteries in series welding up to 3/16" in single pass(thicker than that required multiple pass). You used a small cordless drill attached to the spool gun to feed the flux cored wire from a 2LB wire spool via a basic gearbox. It also had a provision for using shielding gas to allow ALuminum to be welded. Saw it at a fishing industry tradeshow, I think it was called a "Migmate"

 

[Syncro]

Pic #1

OK, I put three 12v batteries in series and it worked extremely well! I was amazed on how good a weld was made by the pure smooth DC current. This is a pic of the setup just prior to welding on some street numbers.

 

[Syncro]

Pic #2

The only problem I had was using cheapo jumper cables that didn't always make good contact. If I was to do this on a regular basis I'd get some short heavy cables with battery terminal ends and use a proper stinger. A few times I had the arc weld the rod to the flimsy jumper cable clamp I was using.

 

[Syncro]

Pic #3

I made about a dozen 1/2" welds using 1/8" rod. All welds were very nice in appearance with PLENTY of penetration. The cheap jumper cables got kinda hot, but I'd say even with that there would be a pretty long welding session providing the cables were let to cool between welds. I feel very comfortable using this setup.

 

[Syncro]

Pic #4

The finished product.

I want to thank all for the help as I never would have thought of using car batteries had I not read about it in this forum. /forums/images/graemlins/laugh.gif
In a pinch, and especially where there is no power it sure can do a fine job.

Also, I tried using only two 12v batteries instead of three and found the results surprisingly good. When I got back to the shop I hooked 2 batteries together using heavier cables and was able to get almost as good a weld. Striking and keeping an arc was a little tricky, but not too bad and certainly works. The trick is using good heavy cables that are short and make good contact with the terminals.

 

[BB_TX]

Great job. And what a beautiful place. Looks like you superimposed a gate on a picture post card.

 

[Mike_C]

I suppose it's a little late for this comment, but in the future be aware that when drawing hundreds of amps from a car battery they give off large amounts of hydrogen, so I probably would avoid battery welding indoors.

That's a beautiful area, I would love to retire on 1000 Acres there.

 

[bobodu]

I was just thinking the same thing about the post card....
Actually got Tami outta her chair to see it!
I told her there wasn't a tractor in sight...geez...

 

[ocaj11]

Nice job Synchro!! As the others have stated, you have a beautiful view with the mountains in the background.

 

[AMP762]

Maybe a little late,but thats where I am most of the time.Snap-on sells a small hand held wire welder that uses two bat.,works very well.