Alternator To Welder Conversion

[Weldtutor]

A schematic, or other information for alternator conversion to welder, is required.

The unit is a 120 amp alternator from a 3.3 L. Chrysler engine as pictured below.

Suggestions appreciated for modifying this specific unit to be suitable for welding.

[vladdy]

I did a couple of older gm alternators way back, bypass the regulator and feed full power to the field, remove the internal diode block and hook up a heavier external set of six..those surplus bolt like ones from princess auto i think was what I used..
they worked ok, didn't do any meter checks, but seemed to be a higher voltage with lower amp than a standard welder, either motor driven or 220v AC old style..
more spatter, and loaded the belt pretty hard on arc strike, two belts seemed to be ok, never tried serpentine but it should be better

enjoy..

[Al_The_Man]

It also depends on what type of welding you intend doing, the Characteristics between stick and MIG welders are quite different, the stick welder is termed a constant current type as although the open circuit voltage is higher (about twice) than a MIG, the voltage ' droops' on load, controlling the current, the MIG is lower open circuit voltage but has a more constant voltage/current curve.
Al.

[Weldtutor]

It also depends on what type of welding you intend doing, the Characteristics between stick and MIG welders are quite different, Al.

A schematic or diagram was really what I was hoping for.

The alternator modification information sought, is to allow for Shielded Metal Arc Welding (SMAW), which is my intention, not Gas Metal Arc Welding (GMAW).

I'm quite aware of the output characteristics commonly used for each of these processes.

Voltage sensing wire feeders can be used with constant current power sources, to provide somewhat suitable conditions for the second process referred to.

[Al_The_Man]

In order to suggest a hook up or modification your requirements need to be known, Type of voltage required? How much control etc. Is it going to be controlled by constant rpm etc.
Al.

[Weldtutor]

I did a couple of older gm alternators way back,
enjoy..

Thanks Vladdy,
The alternator I pictured may have internals similar to the GM ones you did.

Has anyone here modified the unit (Chrysler) pictured in post #1?
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Answers Sought, Debate Not

[gmfoster]

+alternator +welder search turned up several diy articles most of which were GM based.

[Weldtutor]

+alternator +welder search turned up several diy articles most of which were GM based.

Thanks gmfoster,

I've also tried the "weldernator" search but only found results so far for the GM & Ford units that others have modified.

The concepts of course would be similar, regardless of brand.
My hope was to benefit from someone's experience with an alternator the same as the one I'd like to rework.

[2muchstuff]

I know that the older Mopar alternators (cast aluminum housing) from years past used an external voltage regulator. Some of the alternators from V8's came with a dual v-belt pulley on them.

[Weldtutor]

(cast aluminum housing) from years past used an external voltage regulator. V8's came with a dual v-belt pulley on them.

Thanks 2Much.
I may look for that style if this one does not work out. It's from a '93 & is fitted with the pulley for a serpentine belt.
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If I weld it real good, it won't pry loose. (I hope)

[2muchstuff]

I like your signature.

[lwill]

If I weld it real good, it won't pry loose. (I hope)

There is also the saying:
"A good welder grinds before he welds."
But this may apply more:
"If you can't weld good, weld A LOT!"
(Not real helpfull here, but it is funny)