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Welding off two truck batteries
I am looking at options for welding in the field (say in an off-roading setting). I plan to install a second battery on my truck, and with the dual (2x 12V ) setting, thinking of using a MIG spool gun (like those used for Alu MIG) but with flux core wire, so no gas needed. All I need is to somehow regulate the current to say, 125 Amps or whatever, and it should work, right?
This would be useful if I need to do off-grid emergency repairs. I have an onboard compressor that can drive air tools, so can cut and clean steel to prep for welding.
Any thoughts?
HTP Invertig 221H w/ CK20 water-cooled torch • Lincoln PowerMig 210MP • Hypertherm PowerMax 45XP • Optrel Crystal 2.0
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Re: Welding off two truck batteries
Sounds like an interesting idea. If I was more electrical savvy I might be able to suggest a way to limit and control the voltage and amperage up and down. Voltage regulator ??? Resistors or other regulating components to dial the amperage up or down. Typically amperage is regulated through wire feed speed. Not sure how that is done in the machines though.
Last edited by N2 Welding; 08-25-2021 at 01:04 AM.
Lincoln, ESAB, Thermal Dynamics, Victor, Miller, Dewalt, Makita, Kalamzoo. Hand tools, power tools, welding and cutting tools.
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Re: Welding off two truck batteries
I used to carry an electrode holder and some cables so I could wire two batteries in series. That was for ARC (stick) welding - I never thought about a deluxe (FCAW) emergency setup.
Any particular reason you want the added complication of wire feed control?
I would not be at all surprised if there is an inverter FCAW that runs (briefly) from 12 or 24 volts. Or an ARC welder for that matter.
Jack
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Re: Welding off two truck batteries
Voltage sensing wire feed is all you would need. IIRC I've seen a VS spoolgun for just such a use. I cant remember where now of course.
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Re: Welding off two truck batteries
"Ready welder"
Around 600 bucks.
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Re: Welding off two truck batteries
Learn to weld with stick, much more reliable for something like that.
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Re: Welding off two truck batteries
Originally Posted by
koenbro
I am looking at options for welding in the field (say in an off-roading setting). I plan to install a second battery on my truck, and with the dual (2x 12V ) setting, thinking of using a MIG spool gun (like those used for Alu MIG) but with flux core wire, so no gas needed. All I need is to somehow regulate the current to say, 125 Amps or whatever, and it should work, right?
This would be useful if I need to do off-grid emergency repairs. I have an onboard compressor that can drive air tools, so can cut and clean steel to prep for welding.
Any thoughts?
I picked an old Century portable mig machine out of the landfill, several years ago. It runs off of two 12 volt batteries, and lays down a very smooth bead. I'm assuming the drive motor is 12 volt, and has speed control. You can, probably, find a cheap speed control on Amazon that you can wire up to control the wire feed on the spool gun after you determine what voltage the drive motor requires. Doubt you need to control voltage.
Last edited by Weldordie; 08-25-2021 at 05:43 AM.
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Re: Welding off two truck batteries
Wire feed welding off of two car batteries appears
to be doable. The Go-welder and the Century portable
welder both have satisfied users. Maybe an old fluxcore
welder could be hacked up to make a portable wire feeder.
Drive motor voltage may be an issue.
Seems like stick welding with two car batteries could be
frustrating because of low open circuit volts.and no current
control.
Miller a/c-d/c Thunderbolt XL
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Re: Welding off two truck batteries
Neat project, keep us posted on your progress and be sure to post up video of it welding!
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Re: Welding off two truck batteries
I believe this to be correct information but I can't remember the place where I read it. During WWII many Jeeps (and probably other vehicles) had 24 volt electrical systems. There was some sort of field kit available to allow arc welding repairs to be made on the spot. Must have worked fairly well.
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Re: Welding off two truck batteries
X2 regarding ReadyWelder. Got mine for a reasonable price on Ebay. Has saved my bacon (& wheeling buddies) many times.
Millermatic 255
Everlast Typhoon 330
Ready Welder I
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Re: Welding off two truck batteries
Generator? Problem solved.
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Re: Welding off two truck batteries
There is an old hippie, ran for a while a solar company in the day before grid connection. The battery of choice for off grid storage was always golf cart batteries. These are 6 volt high capacity batteries. This guy now runs around with a small pickup load of these batteries & welding leads.
It is my sense that you'd need a lot of big batteries to supply the energy need for welding. I'd think 12 healthy golf cart batteries, six in series, two parallel banks would make a nice weld. You'll need current control to weld well.
Wire feed processes need voltage control to work well whether MIG or flux core.
An optimist is usually wrong, and when the unexpected happens is unprepared. A pessimist is usually right, when wrong, is delighted, and well prepared.
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Re: Welding off two truck batteries
Originally Posted by
Weldordie
I picked an old Century portable mig machine out of the landfill, several years ago. It runs off of two 12 volt batteries, and lays down a very smooth bead. I'm assuming the drive motor is 12 volt, and has speed control. You can, probably, find a cheap speed control on Amazon that you can wire up to control the wire feed on the spool gun after you determine what voltage the drive motor requires. Doubt you need to control voltage.
IIRC, Snap-On peddled these units in the 80's with their brand for about 5 times Century's price. Saw one on a Cat dealer service truck, the mechanic wasn't much of a welder but liked it for fixing small stuff. The truck had a pair of 8D batteries setup for 24V jump starts or running the welder.
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Re: Welding off two truck batteries
Originally Posted by
Oscar
Yup, but at that point you, by the time you nickel-and-dime yourself to death with all those parts, might as well build a miniature "off grid" set-up to get yourself 240V/120V AC power from an DC-AC Inverter just for welding. Or a healthy sized generator and call it a day.
As I mentioned, I just used an electrode holder to ARC weld with two batteries. Obviously, there is not enough energy to rebuild a trailer or repair a truck frame but there was enough for quite a few spot welds to get me out of trouble.
Jack
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Re: Welding off two truck batteries
Originally Posted by
Oscar
Yup, but at that point you, by the time you nickel-and-dime yourself to death with all those parts, might as well build a miniature "off grid" set-up to get yourself 240V/120V AC power from an DC-AC Inverter just for welding. Or a healthy sized generator and call it a day.
Well Gee! I never said I'd do it. If I'm going to throw money away, it won't be on a boatload of batteries to weld.
An optimist is usually wrong, and when the unexpected happens is unprepared. A pessimist is usually right, when wrong, is delighted, and well prepared.
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Re: Welding off two truck batteries
Originally Posted by
Oscar
Generator? Problem solved.
I do not intend to carry a generator so a full blown 120/240V welder is out for now.
Flux core with 24V should be doable unless i am missing something, and it would be the lightest, most portable solution. Wouldn’t expect a lot of welding in the field but if something breaks it’d be nice to be able to join it back together. Just a few inches of weld.
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HTP Invertig 221H w/ CK20 water-cooled torch • Lincoln PowerMig 210MP • Hypertherm PowerMax 45XP • Optrel Crystal 2.0
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Re: Welding off two truck batteries
I can't believe nobody knows about premier power welders? My dad had one when we four wheeled alot, they run off of the special alternator not batteries. You can use any process and enough duty for pretty big jobs axle tubes, weld entire spring packs together crank'er up and cut tie rods off. plus the better model has an A/C inverter to make 120v. Plus the hand wound alternators are world famous alone and will be the last one you ever buy. Dads answer to all these problems was to just stop offroading and sold the Bronco.
https://premierpowerwelder.com/shop/...timate-system/
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Re: Welding off two truck batteries
Originally Posted by
BMX Welder
I can't believe nobody knows about premier power welders? My dad had one when we four wheeled alot, they run off of the special alternator not batteries. You can use any process and enough duty for pretty big jobs axle tubes, weld entire spring packs together crank'er up and cut tie rods off. plus the better model has an A/C inverter to make 120v. Plus the hand wound alternators are world famous alone and will be the last one you ever buy. Dads answer to all these problems was to just stop offroading and sold the Bronco.
https://premierpowerwelder.com/shop/...timate-system/
In my case:
Premier Power Welder, the Ultimate Under Hood Welding System
Complete systems starting at $1299.95
300A Ground Earth Clamp Stick Welder Cable For MMA ARC Welding Inverter Machine
$29.00
Jack
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Re: Welding off two truck batteries
I had a zena underhood welder. It welded well. I ran mine piggyback off the vehicle alternator. Biggest issues... Initial setup. High welding amp equals high torque equal belt slippage. And it sucks when you have to do maintenance or sale the vehicle. Finally, not much accessory space under the hood of modern vehicles.
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Re: Welding off two truck batteries
Originally Posted by
Jack Ryan
In my case:
Premier Power Welder, the Ultimate Under Hood Welding System
Complete systems starting at $1299.95
300A Ground Earth Clamp Stick Welder Cable For MMA ARC Welding Inverter Machine
$29.00
Jack
To any serious off roader that's 1/3 the cost of a set of disposable tires. or half of a tow/impound if the forest service has your rig drug off.
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Re: Welding off two truck batteries
Originally Posted by
BMX Welder
I can't believe nobody knows about premier power welders? My dad had one when we four wheeled alot, they run off of the special alternator not batteries. You can use any process and enough duty for pretty big jobs axle tubes, weld entire spring packs together crank'er up and cut tie rods off. plus the better model has an A/C inverter to make 120v. Plus the hand wound alternators are world famous alone and will be the last one you ever buy. Dads answer to all these problems was to just stop offroading and sold the Bronco.
https://premierpowerwelder.com/shop/...timate-system/
Like others pointed out, i am unpersuaded by the value proposition. I want a spool and minimal voltage regulation of spool/wire speed. Maybe can do it under $300?
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HTP Invertig 221H w/ CK20 water-cooled torch • Lincoln PowerMig 210MP • Hypertherm PowerMax 45XP • Optrel Crystal 2.0
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Re: Welding off two truck batteries
Originally Posted by
koenbro
Like others pointed out, i am unpersuaded by the value proposition. I want a spool and minimal voltage regulation of spool/wire speed. Maybe can do it under $300?
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Have you priced out a power inverter? You can get a 2000 watt inverter for under $200 on Amazon. 15A at 120V is 1800W. Not sure about the duty cycle on them, but it'd be plenty for using a 120V wire feed welder for a quick repair plus you can run power tools. I have an inverter in my truck. SUPER convenient. I carry an air compressor and an extension cord in my truck. Had to use it a couple times. Nice to be able to plug battery chargers in, too. I wired it through a relay and to a switch on the dash, so I don't end up with a dead battery if I leave something plugged in.
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Re: Welding off two truck batteries
If you do get an inverter, make sure you get 2000W continuous, not peak/surge. Also, you need some BIG wires. 2000W 12V is just shy of 170A. So, like 2/0 cable.
https://harborfreight.com/automotive...ter-63429.html
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