spot welder

I needed a new transmitter pack for my old JR X347. I went to Fry’s and got a pack of 8 2750mah NIMh cells to replace the old 600mah nicad pack. I don’t fly anymore, but these packs are for testing Victor motor controllers that I rebuild for the Combat Robotics crowd. In a couple of weeks Combots will be at the San Mateo Fair Grounds again!!

Here are the first 2 cells getting spot welded together. I had no fixture so I used this block and some scotch tape. I cut up some .010″ nickel strips to spot weld the pack together. The settings on the welder worked fine for this thickness of nickel.

Fold them in half.

Push them together.

Now I’m spot welding pairs of cells together.

I added the next pairs of cells to spot weld.

Here is the finished JR X347 pack.

I took the old JR X347 cells found the dead one, added a good one to them and made this my Futaba AM transmitter pack. Note that the settings on the spot welder are lower. These nickel tabs are recycled from the old Futaba pack.

Here is the new cell being charged by itself to bring it up to the same 100% state of charge that the other cells are at.

I wonder if it’s even possible to spot weld aluminum with my spot welder? It is not as conductive as copper, but is far less expensive. Copper has at least tripled in the last couple of years. So I will start with trying to spot weld some aluminum foil from the kitchen and see how that goes. It’s cheap and easy to use for proving the concept, one way or the other. I will still be trying to spot weld braid as well.

Here is the finished spot welder. I sure like the way the LCD display is shining through the smoked acrylic. When it’s off it’s hidden. With the foot switch jack is in the rear and the LCD behind the smoked acrylic, the front bezel is kept very clean. The knobs blend in nicely. This will be the smallest chassis this welder has even been built into. The tight confines did create some EMI issues however.

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