Jeffrey Henderson | DIY Miniature Wire Spot Welder | Precision Wire Frame Modelling System | Part 1

Hi Everyone,
So, it's been approximately 3 weeks since my last video, as some may know, is quite a turnaround given that the baby is now here. Ok, so I've been quite busy with both this new project shown here and the several other projects that I'm now attempting to cover on my channel.
So, this unique project is something that came into my head whilst I was videoing my most recent project for my girlfriend. Interestingly, this new system was designed and created exclusively to benefit the assembly of that project, and to bring more creativity to my channel and for the gift to her seen here.
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So, rather than using my TIG welder to fuse the special piece together, I decided to yet again use multiple adopted microwave transformers to create a system that can weld a distinctive wire frame together as seen in this video. Moreover, the system is designed to adjust between different bar diameters depending on the user’s requirements.
In finer detail, the last video I uploaded was part 1 of a new model am building for her. If you haven’t seen this video, it involves me shaping, bending, and rolling all these bars and rings to match a template I created. Hence, when these stainless-steel bars are all welded together, it will form a 3Dimentional structure in the shape of a large heart representing love.
Ok, so I decided to go against using the Tig to weld this model together, as I wanted no welds visible. Also, I wanted to keep heat to a minimum level as the model could end up warping or becoming inaccurate not matching the template. Therefore, my brain went into overdrive, and I thought about creating my own miniature, crimping, merging, wire spot welder/bar welder that is capable of sliding in and out of at each of the 4 positions of the 40 rings to weld them to the four wire support frames.
The main reasons behind my idea were to eliminate the need for rods during the welding process and to make the project more appealing (less structural and more sculpture) to the eye. In addition, the system created here requires a lower temperature, whilst being highly effective, accurate and efficient. The lower temperatures/short pulse removes distortion of the entire piece and eliminates parts from being damaged that were time consuming to manufacture.
As seen in the video laid out on the table, I had sourced adequate items that were sufficient in building this small mechanism/machine. The initial idea was to remove a microwave transformer and to modify it to produce a high current, enough to turn a thin metallic substance to molten liquid at the material’s surface. Originally, I was not going to show the modification on the microwave transformer from the appliance, as I have done this before for another project (DIY Resin Rubber Grooving Machine Designed for My Smart Gloves) on my channel seen here.
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Anyway, I decided to do this again for this project, as the other projects requirements were different, as the transformer was used for a different purpose altogether. Therefore, once the transformer’s high voltage secondary winding was stripped out, I modified the secondary winding to produce a very high current and a low voltage required of a welder.
The system initially used one transformer producing 800amps at the modified output but was later updated with an additional transformer to increase weld current as seen in the video. The two transformers were altered and wound in series to match the output needed of a welding machine (Low voltage - High current). During this stage, the transformers were carefully placed together, whilst the secondary windings were wound using 25mm^2 welding cable to create a series connection between the two devices increasing the current respectively. Thus, the current seen on the clamp meter was approximately doubled. Welding cable was selected over standard tri rated cable to increase the conductor’s amperage rating and to provide a more powerful machine.
Multiple videos (Part 2 and Part 3) will follow on this project in the weeks to come. Part 2 will focus on the smart handheld device described in this video and part 3 will concentrate on the enclosure that will contain the transformers and circuitry.
The welder will then be demonstrated welding the in-depth 3D heart model frame seen in this link below. A video Part 2 will also follow on that project for my girlfriend using this developed system.
If you haven’t seen my video of my homemade pneumatic spot welder, please do so in the link below. A shorter video will follow on this special pneumatic spot welder in due course without focusing on any lengthy design.
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Enjoy the video 😊.
Peace out and much love! Jeffrey
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