Welding 101: a Primer on Welder Generators

Welders are one of the most highly demanded types of working professionals in today’s world. Their skill set takes some time to learn, and the tools they need to perform their job require careful use.

One such tool in the welder’s armory is the welder generator. These generators are specially formatted to supply the current used by welders. Here is how this crucial generator model fits into the topical profession of welding, and how it can be created:

-Take four flange-mount wheeled casters, and set them at four corners of a thin four-foot long wooden board. Drill holes in the board for each mounting hole in the casters.

-Turn the board over and set the engine on one of its ends. Mark the mounting hole locations.

-Mount a pulley atop the engine shaft. Use a metal bolt to run through a piece of angle iron, one of an alternator’s mounting ears, and a second piece of angle iron. Secure this attachment with a washer and nut.

-Set the alternator on top of the wooden board, keeping the angle iron down. Place an automotive V-belt so that it slides over the engine pulley and alternator pulley. Drill and bolt the two pieces of angle iron to the board with two bolts per angle iron.

-Bolt a turnbuckle to the alternator, and drill a hole in the generator’s mounting board past the turnbuckle’s opposite end. Complete the mechanical assembly by tightening the bolts and belt.

Now comes the electrical assembly of the generator—this process is quite tricky, but some insight into how it could be done follows.

-Take a small car battery, and place it on the board. Mount a toggle switch to the board, and use 12-gauge wire to connect from the switch to a positive battery terminal. Then, connect more wire from the switch to a field terminal on the alternator.

-Obtain a welding ground cable. Connect it to the alternator’s case ground. Then, acquire an electrode holder welding cable. Connect it to the bat terminal of the alternator.

-The electrical setup should now be complete! All that is left is to test it out to be sure that everything is working properly.

-Start the engine and turn on the switch. Congratulations! You are ready to begin welding with this homemade generator.

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