How to Build a Simple ARC Welder.

Supplies:
120v transformer
6 Gauge wire or other thick insulated wire
A hack saw, grinder or chisel
Rubber mallet
120v wire
120v switch
Pliers or wire strippers
Board
Metal box

Estimated build time: 35 min

A short video: http://youtu.be/wwAyC4E-4wQ

Find a Transformer

You will need a large transformer, about 4" by 2" by 4". These are found in microwaves, electric mowers Etc.

Remove the Base

Use a hacksaw, grinder, or chisel to break one of the welds holding the base to the body. Remove the base.

Remove the Coils

Remove the main and secondary coil. You will need to larger wired one, so be careful. The smaller wired and mid coils are unnecessary.

Reinstall Main Coil

You will now reinstall the main coil onto the transformer. Simply slip it back on, and push it to the bottom. Sometimes the use of a rubber mallet is required. This is ok, just be sure to not injure to coil.

Install a 6 Gauge Wire

Find a 6 gauge wire, or any (insulated) wire or bundle that will fit snugly around the center "pillar" of the transformer. You will wind this once.

Re-Assemble

Use epoxy, a welder, Jb welds or even duct tape to reattach the base.

Add a Switch

Find a 120v power cord that is Un-needed. Cut it to a desired length, and make sure to not cut the plug off. This will be needed to plug into the wall.

Splice the wires, and find 2 connectors that will fit on the coil leads. Once your wire is spliced, take one of the leads and chop it to about a foot. DO NOT CUT THE GREEN ONE. IT IS THE GROUND. It does not matter which of the others is cut.

Attach the shorter wire to a terminal on a 120v switch. Take the piece you chopped of and add it to the other terminal of the switch.

Attach the clips that fit on the transformer to the wires.

Mount It

Mount the switch in an electrical box, and the transformer on a piece of wood.

Attach Conducters

Attach a conductor to each end of the coil of 6 gauge wire that is running through the transformer. I used 2 welding rods.

Try It!

Put in some rubber gloves, check for bad connections and turn it on! It will buzz, and when the leads coming off the 6 gauge wire touch, they will spark fantastically and easlyelt coins and nails.

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I take no responsibility for any injuries caused by this post or in direct relation to it. Have fun!!