Onboard welder using a GM Delco 140 Amp alternator

out of a '94 Chevy Camaro

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The mounting bracket

Since I already had an onboard air compressor installed that used the serpentine belt I had to drive the second alternator off the stock one using a combo serpentine/v-belt pulley from Brad Kilby:

I also installed a v-belt pulley on the weldernator since it originally came with a 6 groove serpentine pulley. For the bracket I used a piece of 5x7x1/8 inch thick plate with ears welded on it for the alternator to mount on and another pair of ears on the back to mount on the top ears of the air compressor.

This is where it will mount and the half finished bracket:

This is the finished bracket with dual adjusters and a top brace. The second picture shows the finished connections including the control box. Note how little space is left around the alternator.

This is the simple control box. It ended up to be too small with the relay and the thick cables running inside. It contains a 30A automotive relay, a 10A fuse holder, a lighted 30A rocker switch and two female welding lead quick connect sockets. I will probably upgrade to a larger box that will accommodate a panel voltmeter and a 110V outlet.

Finally my first bead with a 1/16 rod at 45V on 1/16 inch thick sheet metal and another one on 1/4 pieces with 1/8 rod at 85V:

 

Warning:

If you are welding on your own vehicle you must connect the electrode holder to the positive (+) terminal, otherwise you'll short out your battery and charging system. Sometimes you'll need to use different polarity for different rods and positions but you must remember this when welding on your own vehicle.

 

So that's it. I've learned a lot from this project and as always it's not quiet finished yet. I have to get some practice time under my belt also so when the time comes on the trail I can be confident in my repairs. If you have any questions just e-mail me.

Other onboard welder installations:

Damon Gentile's weldernator - he was of great help to me throughout the project.

Dave Goodale's welder - he uses a 108A Delco out of a Buick and made a great looking control box.

Jon's welder, he also made a portable shop alternator welder.

A good write-up on Trailhead.com

A home built gas engine powered welder using a 100A Chrysler alternator.

And just for fun a home built electric arc welder with great instructions.

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