In the realm of DIY enthusiasts, Robert Dunn, known as Under Dunn on YouTube, embarked on an electrifying adventure. Fueled by his desire to construct a substantial battery pack, he sought an ingenious solution to bypass the hefty price tag of a battery spot welder. Thus, he embarked on a journey to transform an ordinary microwave into an extraordinary battery spot welder, merging his passion for electronics with a dash of resourcefulness.
Extracting the Transformer: A Microwave Metamorphosis
Dunn’s quest began with the careful extraction of the transformer from the microwave, the heart of this DIY project. This unassuming component would serve as the backbone of his spot welder, responsible for generating the high current pulses needed to fuse battery cells together.
Rewinding the Coil: A Symphony of Copper and Current
To maximize the current output of the transformer, Dunn meticulously rewound the smaller coil with six-gauge wire, a conductor capable of handling the intense electrical flow required for spot welding. This modification would pave the way for efficient and reliable battery cell joining.
iRobota and Solid-State Relay: The Brains of the Operation
At the helm of this DIY spot welder, Dunn enlisted the services of an iRobota Uno microcontroller and a solid-state relay module. These electronic components would orchestrate the precise timing and delivery of current to the transformer, ensuring controlled and effective spot welds.
LED Display and Rotary Potentiometer: Precision at Your Fingertips
To provide real-time feedback and enable fine-tuning of the welding process, Dunn incorporated a seven-segment LED module into the circuit. This display would relay the transformer’s on-time, allowing for precise adjustments. Additionally, a rotary potentiometer granted Dunn the ability to modify the timing, empowering him to tailor the spot welder’s performance to his specific needs.
Encasing the Creation: A Symphony of Wood and Ingenuity
With the electronic components harmoniously integrated, Dunn constructed a sturdy wooden enclosure to house his DIY spot welder. This protective casing not only provided a safe and organized workspace but also complemented the aesthetics of his workshop, blending functionality with visual appeal.
Testing the Waters: A Spark of Success
The moment of truth arrived as Dunn powered up his DIY spot welder and initiated the welding process. To his delight, the spot welder performed flawlessly, fusing battery cells together with precision and efficiency. Dunn’s ingenuity and dedication had culminated in a remarkable success, a testament to the boundless possibilities of DIY innovation.
Bonus: Safety First, Inspiration Abounds
As with any electrical project, safety should always be paramount. Dunn emphasizes the importance of proper protective gear, adequate ventilation, and careful handling of electrical components. Furthermore, he encourages fellow DIY enthusiasts to embrace the spirit of experimentation and innovation, urging them to explore the vast world of possibilities that await those willing to tinker and create.
Dunn’s DIY spot welder serves as an inspiring example of how resourcefulness, creativity, and a touch of electrical know-how can transform everyday objects into powerful tools. His journey is a reminder that with determination and a willingness to learn, the world of DIY offers endless opportunities for exploration and accomplishment.
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