Spot Welder from a broken microwave Part 4

Part 1 – Microwave Disassembly

Part 2 – Modifying the Transformer and testing the theory

Part 3 – Collecting the parts and preparing the case

Part 4 – Putting the chassis together

Part 5 – Electrodes and Wiring

Part 6  – Final wiring and assembly

 

Cut some holes for the secondary winding cables to leave the case
Cut some holes for the secondary winding cables to leave the case
And some holes for the fuse and main power in
And some holes for the fuse and main power in
First coat of paint
First coat of paint

 

Cut some more metal out from the sides of one of the microwaves to start making a bracket
Cut some more metal out from the sides of one of the microwaves to start making a bracket
and bent them to shape. I bent over the little lip on one of them to slot over the transformer
and bent them to shape. I bent over the little lip on one of them to slot over the transformer
nice fit.
Nice fit. Testing out the new cable glands too
Cables nice and snug
Cables nice and snug
Time to work on the electrode holders. I'm opting for plain old wood instead of metal here just for the safety factor.
Time to work on the electrode holders. I’m opting for plain old wood instead of metal here just for the safety factor.
Found some scrap aluminium that I will use to make my hinge and brackets
Found some scrap aluminium that I will use to make my hinge and brackets
Pulled the drill press out so I could make sure all the holes were in line
Pulled the drill press out so I could make sure all the holes were in line
Drilled, cut, and smoothed some of the rough edges.
Drilled, cut, and smoothed some of the rough edges.
Vice and a hammer makes them 90 degrees
Vice and a hammer makes them 90 degrees
A little bit of tweaking to get them to fit right, I needed to cut out a little dip to fit over the cable glands
A little bit of tweaking to get them to fit right, I needed to cut out a little dip to fit over the cable glands
Testing the fit, just using a piece of threaded rod cut to length and two butterfly nuts to maintain an adjustable tightness on the movement
Testing the fit, just using a piece of threaded rod cut to length and two wing nuts to maintain an adjustable tightness on the movement.
Handy feature of my belt sander is I can clamp it upside down to the workbench to make some jobs a bit easier. just sanding down this old wood to get a good fit and finish
Handy feature of my belt sander is I can clamp it upside down to the workbench to make some jobs a bit easier. Here I am just sanding down this old wood to get a good fit and finish.

 

I think this came from a couch? This is as good time as ever to reuse it
I think this came from a couch? This is as good time as ever to reuse it
Drilled an appropriate sized hole for the double threaded securing bit
Drilled an appropriate sized hole for the double threaded securing bit
Then drilled a little over sized hole in the top for an extra nut
Then drilled a little over sized hole in the top for an extra nut
Perfect fit
Perfect fit
Two holes drilled into the wood and the case and some roofing screws should hold this in snug
Two holes drilled into the wood and the case and some roofing screws should hold this in snug
Uuuugh, they were a pain to screw in though, limited mobility inside the case.
Uuuugh, they were a pain to screw in though, limited mobility inside the case.
Done, both electrode holders installed
Done, both electrode holders installed
From the inside
From the inside

Part 1 – Microwave Disassembly

Part 2 – Modifying the Transformer and testing the theory

Part 3 – Collecting the parts and preparing the case

Part 4 – Putting the chassis together

Part 5 – Electrodes and Wiring

Part 6  – Final wiring and assembly

 

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