91811 HF Tig Welder FREE 100% working foot pedal MOD!
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  1. #1

    91811 HF Tig Welder FREE 100% working foot pedal MOD!

    Here is a foot pedal modification I have added to the 91811 HF Tig Welder. This can be done in the matter of 5 min. I have been testing this modification for over 5 months now with no welder problems nor problems with the foot pedal. The foot pedal was fabricated with some scrap material. For all those who own this welder and find yourself stuck not being able to weld thin material and end up blown holes through it, not anymore. I have a miller maxstar 140 as well and I find myself never using it because it does not have a pedal, with this mod it will completely change your view on the welding machine TRUST ME! Please feel free to ask questions, I will supply photos upon request, the mechanism is so easy to build I feel I should not make any plans so here you go!

    Notice here in the picture I placed a metal pin on the knob to demonstrate my amperage control.


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    Here is the foot pedal that was made out of scrap material.
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    I like the Weld-Tec torch alot better, doesn't get as hot as the HF torch, the angle of the torch is different as well makes it alot easier!
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  2. #2
    Join Date
    May 2009
    Location
    West Michigan
    Posts
    224

    Re: 91811 HF Tig Welder FREE 100% working foot pedal MOD!

    Creative: Yes
    Economical: Not a chance
    Miller Dynasty 300dx
    Speedglas 9002X
    Miller Spectrum 375 Xtreme
    Lincoln PowerMig 255xt
    Lincoln PowerMig 140c
    Milwuakee Portaband

  3. #3

    Re: 91811 HF Tig Welder FREE 100% working foot pedal MOD!

    This modification is not to compare to any expensive Miller, Lincoln,etc welders but it is for all those out there who have this machine and want to enhance it's performance with little to no money at all. Does it perform like my miller351 at work NO but is it alo't better than turning the knob and just guessing your amperage YES! Like I said I have been testing this mod for about 5 months now with no problems so for me its been pretty Economical.

  4. #4
    Join Date
    Jun 2008
    Posts
    129

    Re: 91811 HF Tig Welder FREE 100% working foot pedal MOD!

    Impressive! How does the cord (bike brake cable?) turn the knob? Is it just friction?

    What does the back of that pedal look like?

    There's always people looking for a super cheap pedal alternative. If you have time and no money, this could be a good solution.

  5. #5
    Join Date
    Jan 2009
    Location
    Tijuana, Mexico / San Diego, CA
    Posts
    156

    Re: 91811 HF Tig Welder FREE 100% working foot pedal MOD!

    Thats a really good idea!
    Miller 252
    Miller 250
    Miller Syncrowave 250
    Esab Plasma Powercut 1250
    HF Basic oxy/act torches

  6. #6

    Re: 91811 HF Tig Welder FREE 100% working foot pedal MOD!

    Ok for now I will give you some simple instructions, however I will make a video of how it works . A video behind the hood wont be until I can find a good camera. But here we go

    What You Need:

    1.Bike Cable ( Wal-Mart 5pk assorted for $4.00)

    2.Spring ( Had one laying around but can be bought at hardware store)

    3. The plastic knob has been pulled off and replaced with a rubber one that I got from an air tool drum sander, the knob was simply pushed on , NO glue or anything> ( Don't know the exact size)>>


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    And yes the bike cable provides friction on the rubber drum.

    Although a pedal must be made you can still assemble this and use some pliers and pull the cable and try it out to see how flawless it works. Once hooked up to a pedal I can push the pedal with my fingers and it will turn the knob with ease. I am currently working on the same mod for my Miller Maxstar 140 as it has a better duty cycle than my 91811 . The foot pedal you see in the picture was is my first pedal. I have a new design, much larger , ball bearing ,setup, tig welded with powder coat finish. I will have pics soon.

  7. #7
    Join Date
    Jun 2009
    Location
    Springfield, IL.
    Posts
    67

    Re: 91811 HF Tig Welder FREE 100% working foot pedal MOD!

    Very clever. Any clod can build a complicated mess, genius is in simplicity.

  8. #8
    Join Date
    Feb 2005
    Location
    Louisiana
    Posts
    1,311

    Re: 91811 HF Tig Welder FREE 100% working foot pedal MOD!

    Good job! I admire those who can build and create their own tools or solutions to existing "problems".
    A few of my toys !
    LinuxMint
    Manjaro

    Miller Roughneck 2E
    Lincoln WeldPak 100
    HTP MTS 160
    Chicago Electric 80amp Inverter
    Victor O/A

  9. #9

    Re: 91811 HF Tig Welder FREE 100% working foot pedal MOD!

    that's friggin awesome

  10. #10
    Join Date
    Jul 2006
    Posts
    43

    Re: 91811 HF Tig Welder FREE 100% working foot pedal MOD!

    I must agree that is very clever. I can't wait to see the new improved foot pedal.

  11. #11

    Re: 91811 HF Tig Welder FREE 100% working foot pedal MOD!

    I'm currently working on the new pedal I will have pics soon. I'm glad to see everyone likes my modification.

  12. #12
    Join Date
    Nov 2004
    Location
    Southern Montana
    Posts
    843

    Re: 91811 HF Tig Welder FREE 100% working foot pedal MOD!

    Pure genius! You saw a need... visualized a solution... and created it. Pure genius!
    Thanks for posting.

  13. #13
    Join Date
    Oct 2009
    Location
    Downers Grove IL
    Posts
    1

    Re: 91811 HF Tig Welder FREE 100% working foot pedal MOD!

    Hey, I have the exact same Harbor Freight welder, and several years ago I made a very elaborate pedal-operated potentiometer control, to replace the one on the front panel. It was a flop; somehow, the circuitry does not take kindly to putting the pot on long wires. Shielding didn't help.
    Anyway, I am flabbergasted to see such a simple, sensible solution. I will definitely do it. Thanks muchly.
    Oh, and don't go tryin' to hook up a Tesla coil to the output cable, for HF arc starting. ("Hi, I need to return this welder....")

  14. #14
    Join Date
    Dec 2006
    Location
    Rhode Island, USA
    Posts
    171

    Re: 91811 HF Tig Welder FREE 100% working foot pedal MOD!

    Great Idea. Get a patent before some guy in China steals your idea.

  15. #15
    Join Date
    Jul 2006
    Posts
    43

    Re: 91811 HF Tig Welder FREE 100% working foot pedal MOD!

    Better still go ahead and put together the cable, spring and foot pedal and sell as a package.

  16. #16

    Re: 91811 HF Tig Welder FREE 100% working foot pedal MOD!

    Hey everyone I'm glad to see you all like my idea. I am currently in the process of moving so I have yet to finish up the new foot pedal.

  17. #17
    Join Date
    Nov 2009
    Location
    North West Pennsylvania
    Posts
    380

    Re: 91811 HF Tig Welder FREE 100% working foot pedal MOD!

    I asked an electrician I know if he could wire a pedal into my unit. The price was more than the machine. I like your solution much better!

  18. #18
    Join Date
    Mar 2008
    Location
    Pinokio Land and blue feri
    Posts
    989

    Re: 91811 HF Tig Welder FREE 100% working foot pedal MOD!

    very handy for a need without equipment situation... I'll stick to a permanent foot pedal...

    thx for sharing
    Unit in my fab shop dept:
    my good hand and team that trust me...

    A lone welder make art... a village full of welder make Miracles...

  19. #19
    Join Date
    Dec 2009
    Location
    Greenville TX
    Posts
    933

    Re: 91811 HF Tig Welder FREE 100% working foot pedal MOD!

    interesting.....is there pre-gasflow before the arc and after on this machine........my Lincoln's gas flows 2 seconds before the arc and for 9 seconds after.........

    thanks for sharing.

  20. #20
    Join Date
    Nov 2009
    Location
    sarasota, florida
    Posts
    43

    Re: 91811 HF Tig Welder FREE 100% working foot pedal MOD!

    Thanks for sharing your concept. I'm goin to try the same thing on my little Marquette TIG welder. Hope it works the same for me. Darrell

  21. #21
    Join Date
    Nov 2009
    Location
    OH
    Posts
    13

    Re: 91811 HF Tig Welder FREE 100% working foot pedal MOD!

    Quote Originally Posted by MJDamiani View Post
    Great Idea. Get a patent before some guy in China steals your idea.

    Probably too late already and I don't think they need to worry about US patents anyway!!!
    Rich

    Lincoln 180 MIG
    Lincoln Pro-Cut 20
    Henrob/Cobra Torch

  22. #22
    Join Date
    Aug 2010
    Posts
    22

    Re: 91811 HF Tig Welder FREE 100% working foot pedal MOD!

    Any updates on this? Still working well?

  23. #23
    Join Date
    Jul 2008
    Posts
    26

    Re: 91811 HF Tig Welder FREE 100% working foot pedal MOD!

    any updates, pics, or vids??

  24. #24
    Join Date
    Nov 2010
    Posts
    277

    Re: 91811 HF Tig Welder FREE 100% working foot pedal MOD!

    I think you should add a break lever to the torch instead of the foot pedal!

  25. #25
    Join Date
    Jan 2009
    Location
    Nolalu (near Thunder Bay) Ontario, Canada
    Posts
    812

    Re: 91811 HF Tig Welder FREE 100% working foot pedal MOD!

    WOW! I guess that Necessity IS the Mother of Invention
    Gordie -- "I believe you understand what you think I said, but I'm not sure you realize that what you heard is not what I meant."

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