Made my first sparks over the weekend and the welder seems to work just fine, although the welder's operator stinks! I've MIG welded here and there at work, but never stick welded. The centerline of the plug end isn't the same as the centerline of the hole for the wire to go in, so you have to make up a way to turn the plug end on-center.Īfter the mandrel was turned down, I flipped the works around and chucked it up in the jaws, set the taper on the cross slide and that was that! So then I turn down the rod using the plug body as the holder until the rod is being cut over it's entire O.D. Oh, first I had to turn down the rod just a bit to fit in the plug body and milled a flat for the set screw. To turn the plugs, I first had to make an eccentric mandrel - I chucked the original plug end in the lathe and inserted a 4" long piece of 1/2" steel rod. copper tubing from McMaster-Carr and pressed on a 1" length and turned it down to match the size/taper I needed. I took the "universal" welder plugs I purchased which were nominally 3/8" diameter, +.010, -.010 taper over the inch long plug. The solution turned out to be rather simple if you have access to a small lathe.
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