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Almond farmer
Junior Member
Last Activity: Yesterday, 09:44 PM
Joined: 11-25-2017
Location: CA
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  • Helios
    got a four year degree BSEE from UC Berkley in 1970 , Then got multiple degrees in mechanical, spent carrier in applied mechanics.
    electrical not electronics because in 1970 transistors were the size of dimes, but magnetics was big back then.
    did not practice EE at a professional...
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    Last edited by Almond farmer; Yesterday, 10:56 AM.

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  • Forney 235AC\DC transformer/choke unit uses covered insulation stranded aluminium wire for primary, secondary transformer windings and choke windings using white colored insulation.

    so what is the best solution for the front lead terminal connection where the electrical path is aluminum...
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  • I know the red colored coating is shellac and used as an insulator on transformer windings and electric motor field windings.
    however , looking from a distance it might appear that your aluminum transformer windings are copper,since the red colored shellac is almost the same color a corroded copper...
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    Last edited by Almond farmer; Yesterday, 12:14 AM.

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  • Answering my own question.
    Yes the 1993-1995 Thunderbolt 225 AC & Thunderbolt 225 AC/150 DC has aluminum(AL) primary & secondary transformer windings and aluminum choke windings on the DC unit verified by cover removal.
    The AL windings are coated with a red colored shellac giving...
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  • 93 thunderbolt lead terminal hardware

    Recently got a 1993-1995 Miller Thunderbolt that supposedly spent its life 4 miles from the Pacific ocean.

    Removed the wheels, handle, cover. Don't know if wheel & handlebar is home brew or Miller factory kit.

    There are five lead terminals on the front panel, +/-dc, low...
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    Last edited by Almond farmer; 12-13-2017, 10:29 AM.

  • Almond farmer
    replied to Tap and die set
    The Irwin's are made in the USA, use 5/16" - 1/2" coarse & fine to clean up threads. When one gets dull, replace it.
    The small Irwin's are not made to actually made to make threads on a steel rod, but work all right on aluminum because the dies are too thin
    To properly align...
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  • The machine was probably reengineered to reduce cost.
    Prefer the older design over the new XL design.

    Al was used for residential house wiring until some fires occured because of extra resistance from corroded aluminum oxide at connections.
    The national electrical code eliminated...
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  • Got the thermal conduction and electrical resistivity from "Matweb".... 50% is approximate.
    The physics of thermal conduction and resistivity are similar.

    The thunderbolt 225 draws 45.5 amps AC while the later model XL draws 47.5 amp AC according to the performance ratings...
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  • Reviewed all the Miller thunderbolt online operating manuals from 1982 to present, except the new inverter based 160 & 210 that have replaced the transformer based thunderbolt line and are no longer manufactured.
    1982 to 1998 , net weight for the 225 AC 150 DC is 114#.
    2000 to present...
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    Last edited by Almond farmer; 12-09-2017, 07:04 AM. Reason: Changed from 5VAC to 5 amp AC

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  • aametalmaster
    Does the vintage Thunderbolt with Cu transformer wiring have the top shut crank and front mounted.
    How is it identified?

    After studying the online Miller operational manuals appears the XL version was introduced in ~1998 with four position selector switch and side...
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  • Thunderbolt & Thunderbolt XL transformers

    Does the Thunderbolt 225AC\150DC with top mounted shunt crank current adjustment use aluminum or copper in the primary\secondary transformer windings and the inductor choke?
    Same question for the Thunderbolt XL ,later model, with front mounted shut crank.

    Understand aluminum has 50%...
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  • Not much interest in this topic, apparently.
    Researched the two types of AC stick welder transformers.

    The Miller method is to use a variable shut on a threaded rod to adjust the magnetic field coupling between the primary and secondary coils using a magnetic material. With the shut...
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  • Almond farmer
    started a topic Classic AC transformer machine CC

    Classic AC transformer machine CC

    Noticed that most AC transformer based machines use a block of metal between the primary and secondary with variable positioning with a threaded rod to vary the constant current output, i.e. Miller thunderbolt XL 225, Forney, Irontron, Vulcan.
    Lincoln AC 225 uses a selector switch with taps from...
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    Last edited by Almond farmer; 12-04-2017, 01:15 PM.

  • Almond farmer
    replied to What size generator
    The specification on most small frame generators state modified sine wave.
    It is not a true square wave with vertical sides.
    This type of generator uses brushes on armature to generate AC.

    Miller technical advised recently that the Bobcat and Trailblazer engine drive welding...
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    Last edited by Almond farmer; 12-02-2017, 01:05 PM.

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  • Found a U Tube video by weldingtipsandtricks when aluminum is welded using a DC coated stick arc rod made to weld aluminum with a constant current SMAW, but this rod is used in GTAW process with TiG torch and argon.
    The bead had plenty of penetration and the crown looked all right, but not the...
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  • Almond farmer
    replied to What size generator
    Have researching the generator requirements to power a classic transformer based and new technology inverter based machine.
    The problem with so called small generators is the output wave form.
    The output is a modified sine wave. Instead of profile that is a perfect sine wave supplied by...
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  • Used to work with a "welding engineer "" ,who developed the actual weld procedures.
    Otherwise have use the trial and error method to establish the weld procedure.
    The pulsing method, mentioned previously, is quite affective in bridging the 3/16" wide gap on the beveled...
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  • Almond farmer
    replied to hole saws
    Is the tank cylindrical with semi elliptical or hemi spherical heads?
    What is the tank diameter.
    If cylindrical the plate can be bent using two square bars on the edges. Get a steel pipe and weld a smaller tube or pipe say 3/4" long where the rod from the bottle jack press fits into...
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    Last edited by Almond farmer; 11-29-2017, 09:34 AM.

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  • Normally the welder is certified to a particular welding procedure.
    Before retiring was a pressure vessel and piping structural stress guy vin oil and gas industry then same type of job in the military and commercial aircraft industry were aluminum is the predominate metal.

    Where...
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  • Almond farmer
    replied to hole saws
    Most threaded tank fittings have a shoulder that fits into the hole with flange on the external surface. Fillet welded between flange and tank wall.
    would take an 8" square carbon steel , 1/8" and cut a hole the correct diameter for the shoulder on a milling machine with rotary turn...
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