welding with batterys for trail repair

[troyboy162]

Arc Welding with 3 Car Batteries (Tutorial & Demo) (http://www.youtube.com/watch?v=8tHJ0NSjZnM#)

seems putting together a little kit would be pretty easy. i always thought this would hurt batteries but it i guess the load is not really that bad on them

[Crinale]

iv seen stuff like this, and it looked really sketchy...

[L33T35T Tacoma]

I've heard of this before, I believe from Roger Brown.

Gotta do what ya gotta do, right? Could you weld a CV axle? lol

[Scuba]

Gotta do what ya gotta do, right? Could you weld a CV axle? lol


No.
The shafts themselves are cast. Meaning they'd need to be extremely hot before you can even lay a weld on them thats going to stick. Think, preheating with an oven.
The part that more commonly breaks however, the outside CV joint, is too precise to lay a proper bead inside or outside of the cage. Not to mention, there is too much grease on that joint that it'd take you half an hour to get it cleaned up without spilling anything into the environment. Its just out of the question to "weld" a cv axle back together. They only cost 50-80 dollars and they only take an hour to change.


Troy, I've known about this for a while now, but have never done the research about what type of rods to use. Then, I'd have to store them and a welding helmet somewhere where I already lack space.
Maybe now that we're frequenting the hammers more often then not, it might be smart to brush up on this technique.

[DHC6twinotter]

I saw this done at the SE4RJ a few years back. Guy broke his hydro steering assist mount off and welded it back on with jumper cables and a couple of batteries. They did use welding rods, but not sure what kind. It worked, and he didn't have any other issues with it.

http://i297.photobucket.com/albums/mm233/DHC6twinotter/Southeast%204Runner%20Jambo%202008/IMG_1822.jpg

http://i297.photobucket.com/albums/mm233/DHC6twinotter/Southeast%204Runner%20Jambo%202008/IMG_1825.jpg

Some guy in a thread over on expo said clothes hangers could be used if you don't have the proper rods. That's just what one person said, so I dunno.

[troyboy162]

its deffinatly a shotty welding style but i read its along the lines of 75 amps to melt a typical welding rod. thats hardly anything when distibuted amoung 2-3 batteries. damaging my expensive ultima battery was my biggest concern really. but with the numbers in mind we are much harder on our batteries when using winches in the rocks.

this post has lots of info on putting a kit together.
http://www.jeepforum.com/forum/f37/putting-together-emergency-stick-welding-kit-trail-use-thoughts-1084559/

you can buy a kit here for a stupid price
http://www.dnaoffroad.com.au/products.php?product=12%7B47%7D24V-battery-ARC-welding-kit

i think i will try to put something together soon. nothing fancy but just for those times when someone needs it.

[4x4mike]

I've seen it done a couple of times and know some who carry the supplies. You kind of have to know what you're doing to not mess yourself up or your batteries. Prep is a big portion of the work as well. Might as well have a large enough inverter to run a grinder and carry scrap steel to make proper repairs. I've seen wrenches welded to broken frames and the like. Again they are field repairs and sometimes the only option to get you home. Welding rod is small but you do have to carry different types for different repairs.

If I were to setup anything it would be a weldenator or find a used premier power welder. The weldenator is a second or modified alternator used for stick welding. it's already on board, no worry of removing and potentially over discharging batteries and takes up less space. I only have a saved picture but there is a mod to put a 130 amp alternator in a 3rd gen 4runner and that would most likely be the ticket for our vehicles.

[4x4mike]

Quick google search

http://www.tamparacing.com/forums/truck-forum/680965-weldenator.html

"weldenators" are all over the internet and think from a cost stand point is the way to go. For now I just carry JB weld and some comfy shoes.

[troyboy162]

ill have to check that out when i get on some normal internet. whats the costs involved? used alt, brackets, extended belt? welding on your own running truck?

[4x4mike]

Cost is a part store alt from a truck (80+ amp), simple bracket, some wiring and a control box. The control box basically turns the alt on and off. In the on position it bypasses the regulator to output the full amount of amps at a lower RPM. If I were to do it's I'd buy a cheap alt with a lifetime warranty and return it when it gave up. Once you have that you need some leads (can be homemade), rod, gloves and a helmet.

Using this method you have your own power source independent of the batteries and probably a little safer. I believe the premier systems are similar although some of their models have an inverter incorporated which would be nice for drills and grinders. Welding on your own running vehicles has it's risks but has been done a lot. Watch for sparks and heat, ecu's, ground points and moving parts. Talk other people into making one as well that way you have two. Say you broke and had to fix a motor mount. Having the engine off would make it a little easier.

[4x4mike]

Here is the swap I mentioned. I thought I had a picture but couldn't find it. Turns out I had emailed myself the link. This is an alternator upgrade. I'm not sure if for a weldenator you HAVE to have a second alt or if you can just isolate the one you have from everything else. If you can get away with one you'd need a larger one like this.

Interesting note: The heated windshield on a Caddy must be serious business if it's powered directly from the alternator. That's my kind of car.

http://ttora.com/forum/showthread.php?t=144170

[troyboy162]

hmmm im liking the idea of only one alt. im pretty ignorant on the subject but could you slap a isolated weldinator in your truck on the trail and start/run the truck on your battery? i dont know if that doable or reasonable.

the thing that drew me to battery welding is the low cost and small size for the kit. i already feel i carry too much junk with all my recovery gear, axle, and tools. the alt welding certinly has lots of benifits though...hmmm

[CJM]

Its easy to do, you dont need to clean anything when arc welding either. However you gotta have a clue how to weld and strike an arc-otherwise you weld the rod to the material rather easy.

[4x4mike]

Troy, I'm not sure I'd want to swap alternators for a repair. I know the frequency of welding repairs is not often but it would be a pain. I think that with a little head scratching you could fit a second alternator in there. If not used for welding it could be used for high output inverter for other tools, etc. I've got a York in my engine compartment and it fits right in after a little relocation of some items. If you've got an auto tranny you've got a little more room than I therefore it might be easier.

Batteries are somewhat easy if you've got a group but it means taking them all out, hooking them up, being careful not to drain them and then putting everything back together. Again because of the frequency it might not be too bad.

Arc welding doesn't need clean surfaces but if you're not great at it having a prepped surface will make a huge difference.

[NakSuKow]

Here is a cool idea:

http://www.jeepforum.com/forum/f37/how-make-trail-mig-flux-core-welder-1096579/#post10054358

[strykersd]

I've seen a certified welder at a local weld shop try this, it's definitely not easy! Definitely practice before it beforehand so you don't have to do it for the first time on the trail!

As for helmets, I've heard of people wearing three or four pairs of sun glasses in a pinch.

[Obi..]

As for helmets, I've heard of people wearing three or four pairs of sun glasses in a pinch.


Unexposed and finished strips of 35mm film roll work also, just stack two of them together..if you have a 35mm camera and not digital. ;)

[Crinale]

Unexposed and finished strips of 35mm film roll work also, just stack two of them together..if you have a 35mm camera and not digital. ;)

Do they even MAKE 35mm film anymore? :flipoff:

[troyboy162]

Hye Krawlers - Welding Trac Bar with Car Batteries (http://www.youtube.com/watch?v=RuLazY5J9RA#)

hye crawlers just put out a good video on it

[Crinale]

nice.. it does look like a good skill to have, and a good reason to keep those tools handy