How to remove hand control on Diversion 180 when upgrading hose

[Jon K]

Hi guys,

I replaced my stock torch with a WP-9 and hose with a weldcraft ultra flexy jobby. I cannot recommend this upgrade enough - WAY more control! The hose and torch are not fighting your grip... love it.

Anyhow, I have my torch and line hooked up, got the adapter for the gas, it welds beautifully, but I couldn't figure out how to detach the hand control and remove the stock hose fully so right now my stock hose and torch are connected via the hand control cable (which I do not use). Anyone done this and know how? I looked and you can unplug it from the board but then the connector will not fit out the front of the machine.

Thanks all!

[trouble007]

You Tube

You Tube

hope this helps

Ryan

[Gamble]

Pics Pics Pics!!!!!
How much was it all? Make a video. I want to do this now!

[900steve]

I've done this mod. I made an adapter that goes inside the machine, so that cost me $0, but I think I have seen someone selling them for about $20 or $30 on YouTube.
The stuff I did was was all inspired by this post:
http://www.offroadfabnet.com/forums/...ead.php?t=7051
Beyond the adapter, I got a flexible cable, a number 9 torch body, and ditched the hand controls. Welding with my Diversion 180 is so much more enjoyable now.

[Scotty 510]

Yep, ordered my fitting from MeanMike over on offroadfab.net $28 shipped, just sign up and PM him.

Scott.

[Gamble]

^^Both you guys went with the WP9 torch as well? So you just change it out if you go over 125amps?
I've seen the torches for as cheap as $10 shipped on ebay. What hose do I need?
Edit: So you guys are using cheap $10 china torches or the $75 weldcraft torches?

[Jon K]

I went with a weldcraft torch and weldcraft hose. Supposedly nothing wrong with the $10 torches but, I figured hell...

WP9 is awesome!

[Gamble]

Where did you get them from?
So if I'm reading this correctly you need the torch, hose and the connector that the guy made? Do you have to take the cover off the diversion or can it all unscrew from the front? Not too sure how deep I want to dig into my machine, especially if it voids the warranty.

[900steve]

The entire cover comes off. You'll also have to remove the handles in the process, and the front plate remains attached to the machine.
I got my hose from Arc-Zone through their eBay store with the torch. It is the Pro-Kit in the options you have when you configure your kit. It's a very light weight hose and very comfortable. I'll run the WP9 up to 130 or on occasion 140 Amps, but briefly since it will get hot. If I know I'm going to be hovering up there at the machine's duty cycle limit I will switch out to a WP17.

[Joker11]

My buddy has the Diversion 180. I can't understand why there isn't a kit to add a water cooled torch. I would be making one myself. Air cooled is fun for a couple seconds. Then I want to put my hand on ice.
Water is the way to go.

[Jon K]

Originally Posted by 900steve

The entire cover comes off. You'll also have to remove the handles in the process, and the front plate remains attached to the machine.
I got my hose from Arc-Zone through their eBay store with the torch. It is the Pro-Kit in the options you have when you configure your kit. It's a very light weight hose and very comfortable. I'll run the WP9 up to 130 or on occasion 140 Amps, but briefly since it will get hot. If I know I'm going to be hovering up there at the machine's duty cycle limit I will switch out to a WP17.

Do you switch the whole torch or just the head to a WP17?

[Gamble]

Originally Posted by Scotty 510

Yep, ordered my fitting from MeanMike over on offroadfab.net $28 shipped, just sign up and PM him.

Scott.

Can you pm him again, I'll take a fitting.

[Scotty 510]

Originally Posted by Gamble

Can you pm him again, I'll take a fitting.

Like I said sign up to the forum and PM him, it's not that difficult lol.

In the mean time watch this, pretty simple DIY.

You Tube

You Tube

Scott.

[Vinnie]

What do you use for a bushing to keep the new fitting from touching the frame? You didn't mention one in the vid.

[Gamble]

Great stuff thanks!
I wonder how people have done it without the custom fitting.

[Gamble]

My LWS store said they can get me a CK torch and cable for $55. That's pretty cheap I may go this route and get the custom fitting.

[Mike E]

Originally Posted by Scotty 510

Yep, ordered my fitting from MeanMike over on offroadfab.net $28 shipped, just sign up and PM him.

Scott.

That's me. Gamble mentioned that a few people here were doing this modification. I've been wondering where all the request for fittings had been coming from lately. I've made nearly 40 of these fittings in the last few years. If you want one, send me an email to edwardsmt@gmail.com.

Originally Posted by Vinnie

What do you use for a bushing to keep the new fitting from touching the frame? You didn't mention one in the vid.

No bushing necessary, it all fits inside the strain relief on the machine. The fitting was original on my Diversion 165, but that's probably because I bought one of the first few machines made back in late 2009.

[Mike E]

Originally Posted by Joker11

My buddy has the Diversion 180. I can't understand why there isn't a kit to add a water cooled torch. I would be making one myself. Air cooled is fun for a couple seconds. Then I want to put my hand on ice.
Water is the way to go.

I've figured out an easy way to add a water cooled torch. Basically you would convert the machine over to Dinse connectors and add a seperate fitting for the gas connection. Then you could use any off the shelf water cooler and torch setup.

I haven't done it because I'm afraid that it will only show the next weak link in system. If the torch stays cool, how much longer can you weld before putting the machine in thermal shutdown? If your really welding enough to justify water cooling, you might be a bit above what the diversion was meant to do anyways. I'm probably to that point, but mine keeps on going.

I make sheetmetal valve covers and oil pans and these are a real workout for a diversion. 3/8" flanges and .090" sheet.

[Scotty 510]

Looking good Mike! Thanks again for the fitting, it's like night and day when using my Miller now, highly recommend this to anyone with an 165/180. Hell, being comfortable only makes for better welds in my opinion!

Scott.

[Jon K]

I used my torch tonight and man, still can't get over the difference!

[Gamble]

My torch and cable should be in by the end of next week. I'm super excited about this.
Wondering what I should do with the torch control cable still.

Mike,
You weld 3/8" thick aluminum flanges with the diversion 165 and this torch and cable that are rated for 125amps? How much amperage are you using?

[Mike E]

I put the wp-17 torch head back on when I weld at anything over 125 amps.

For the 3/8 flanges I put the welder at max amps and throttle the peddle. I also use a 75% Ar / 25% He mix.

[Gamble]

Do you change out the cable too or no?

Mike, I got the fitting in the mail yesterday. Looks great, can't wait. My torch and cable should be here tomorrow.
Thanks again!

[Mike E]

No, I just slide the grip off the torch, use two 7/16" wrenches to break the torch/cable connection and swap on the new one. It takes about a minute at most.

[bobx67]

i changed out the thumb wheel torch, looks like this might be the next thing though. im new to tig but figured out quick that being comfortable helps a bunch.

thanks.