Did you DIY your water cooling system?

[DaveO]

I'm thinking about how I'd assemble a water cooling system for a TIG welder, and looking for tips and tricks.

I just picked up a small submersible 110v water pump, and it seems like that thing in a 5 gallon bucket should do the trick. I'm also thinking about using a heat exchanger of some type, maybe from a dehumidifier.

I've read other posts talking about using a automotive water pump- what else have you used or improvised to make yours work?

Thanks!

[WILD BILL]

I'm currently researching parts for one.

when I get it all sorted out I'll post the results.

So far it's looking like I'm using these parts,

http://www.grainger.com/Grainger/LIT...ner-Pump-2P018

http://cgi.ebay.com/ws/eBayISAPI.dll...=STRK:MEWNX:IT

http://cgi.ebay.com/6-FT-PC-Computer...86883749933140

With just under 2 gallons and the limited welding I do I doubt I'll need a heat exchanger but if it turns out I do I may pick up a small rad from

http://www.dangerden.com/store/black...-radiator.html

Still gotta figure out a possible fan

I'd like to pack it all in one of these

http://www.hammondmfg.com/1453.htm

But so far coming up with one cheap has been a challenge

Then it should just be a matter of plumbing from the hardware store

[DiabolicZ]

I thought about how I'm going to do mine for about 5 seconds last night. I am heavy into aquariums, so I have extra pumps laying around. I am going to rig one of those up in line with something along the lines of an Oil cooler for a car or a fuel cooler. Something aluminum with fins basically.

I would just have the power head (pump) pulling water from the cooler and pushing it to the torch. That way the pump never sees hot water.

[DiabolicZ]

I'm currently researching parts for one.

when I get it all sorted out I'll post the results.

So far it's looking like I'm using these parts,

http://www.grainger.com/Grainger/LIT...ner-Pump-2P018

http://cgi.ebay.com/ws/eBayISAPI.dll...=STRK:MEWNX:IT

http://cgi.ebay.com/6-FT-PC-Computer...86883749933140

With just under 2 gallons and the limited welding I do I doubt I'll need a heat exchanger but if it turns out I do I may pick up a small rad from

http://www.dangerden.com/store/black...-radiator.html

Still gotta figure out a possible fan

I'd like to pack it all in one of these

http://www.hammondmfg.com/1453.htm

But so far coming up with one cheap has been a challenge

Then it should just be a matter of plumbing from the hardware store

Wow, you are going all out! I mean that is cool and all but... you know... why?

Milk jug $1,000,000,000
$10 aquarium powerhead
line and fittings from the hardware store $20 max.
some kind of chiller $20

So a maximum of $1,000,000,050

[WILD BILL]

I thought about the aquarium power heads but couldn't get a concise answer as to weather they would be up to the task. Some say go for it and others say not enough pressure. Most use a procon pump but I could never find the "deals" they say they got.

I got the cord so I didn't have to worry about Making sur I plugged in the cooler before I started.

I want all this relativly compact so that it fits on the bottom shelf of my HF cart and still leaves room for the pedal.

[angular]

http://www.grainger.com/Grainger/LIT...ner-Pump-2P018

http://cgi.ebay.com/ws/eBayISAPI.dll...=STRK:MEWNX:IT

I'd like to pack it all in one of these

http://www.hammondmfg.com/1453.htm

That pump is 110V and the outlet on most Everlast welders (as far as I know) is 220V. Also the max pressure rating is 35 PSI. It seems "geared" more for volume than pressure.

I like that steel enclosure. Any idea what those cost? I need one for my DIY cooler.

Bradley

[WILD BILL]

They do make a 230V version of that pump

http://cgi.ebay.com/Little-Giant-35-...item2561892227

I Was just going to split the phase in the cable so that I didn't have to modify the welder and possibly void my warranty.

Still waiting to see if that Granger pump is in stock. If not I'll probably get the one I just listed.

I'm using 12.5' torch and wont likely ever be welding with it more than a couple feet over the pump so I figure the pressure to raise the water through for my needs wont be to bad.

I will however test it at full rise to test the max I can lift the torch while still getting proper flow of coolant.

Sorry, I have yet to find any retail pricing on that enclosure.

[angular]

Looks like it's $116 at Digikey. Costs add up fast. If I bought that enclosure, I'd be pushing $400 for my DIY cooler. Conclusion: the Everlast W300 is a pretty nice unit for the money.

[WILD BILL]

Looks like it's $116 at Digikey.

I may just leave it exposed or build my own box.

[DiabolicZ]

Looks like it's $116 at Digikey. Costs add up fast. If I bought that enclosure, I'd be pushing $400 for my DIY cooler. Conclusion: the Everlast W300 is a pretty nice unit for the money.

+1^

That is what I was getting at with these super intricate custom coolers. Cost's add up quick, just buy the unit from everlast if you want a decent cooler, and it will match your machine. Or buy one somewhere else... whatever.

I usually tell my wife. "If I can make it for cheaper than I can buy it... I will."

[Wrenchtamer]

I'm thinking about how I'd assemble a water cooling system for a TIG welder, and looking for tips and tricks.

I just picked up a small submersible 110v water pump, and it seems like that thing in a 5 gallon bucket should do the trick. I'm also thinking about using a heat exchanger of some type, maybe from a dehumidifier.

I've read other posts talking about using a automotive water pump- what else have you used or improvised to make yours work?

Thanks!

Not a water pump. I can't think of any that would be suitable for the task. I think you mean fuel pump

[sportbike]

Might be able to use a pump like this:
http://www.surpluscenter.com/item.as...&catname=water

Not sure what the flow and pressure drop requirements are for a torch.

Surplus center always seems to have "useful" items for things like this.

[angular]

Not sure what the flow and pressure drop requirements are for a torch.

50 PSI (max) and 1 quart per minute seem to be the widely accepted figures. The actual PSI required to push 1 quart/min though the torch is going to vary depending on the cables & torch used.

[DaveO]

Angular, that"s a very clean setup, nicely done. Where is that little radiator from? And is that quart jug in back the reservoir?

[Zoomie]

Wild Bill,
Your shop must be pretty noisy or you are always welding in AC! My old man's Coolmate predecessor sounds like a freight train with bad bearings. It is so noisy it is distracting. It's turned off when changing set ups and when the torch is not going to be taxed too much. To each his own I guess. Loud noises aren't usually the killer of hearing, its the continuous stuff that can get ya, and my leads are only 10-12 feet.

[angular]

Angular, that"s a very clean setup, nicely done. Where is that little radiator from? And is that quart jug in back the reservoir?

Here's some info on my set up...

Heat exchanger (radiator):

http://www.summitracing.com/parts/DER-13300/

Procon carbonator pump (part # 111A100F11AA) and it's rated at 100 GPH (@ 100 PSI) or about 1.67 GPM.

http://cgi.ebay.com/ws/eBayISAPI.dll...m=230582068842

The internal bypass valve on the pump doesn't seem to go low enough (without completely unthreading), so I'm using an adjustable relief valve to bleed off excess pressure.

http://www.mcmaster.com/#8088k14

That relief valve is actually pretty nice for the money and easy to adjust by hand, so I'm glad I got it. Excess flow from the pump gets routed through the heat exchanger, so would I imagine around 1.5 gallons per minute are flowing through it at all times.

Pump motor:

http://www.grainger.com/Grainger/MAR...p-Motors-5XB85

Reservoir:

http://www.suremarineservice.com/001-395.aspx

Reservoir is maybe 2 quarts. Worst part is not the volume it holds but the the barb fittings being pretty small so the return flow really "jets" into the tank and tends to foam things up. Overall I would say this cooler is massive overkill for my use!

EDIT: Let me just reiterate this very important point...

The Everlast W300 cooler is a very nice unit for the money and it would be a serious challenge to build something as polished or "turn key" as that for $400. I really hesitate to encourage people to go down the path I went because it's a slippery slope and not really cheaper in the end (if time invested counts for anything). If you're a hardcore DIY type and enjoy this sort of thing, that's cool, but the only real advantage to my setup at this point is a pressure gauge and adjustable pressure regulator.

[WILD BILL]

My garage is usually pretty quiet save for a radio which is why the noise of the welder stands out so much

Using a 2 quart reservoir you would definitely need a heat exchanger which is why I went with the go kart tank. At 7 quarts it should be fine but I'll keep an eye on temp rise just to make sure.

My current line of think is to just mount everything on the bottom shelf of the cart and then add a wall to keep the foot pedal from knocking into it.

I'll be happy to post the build up once the parts arrive i you guys are interested.

[A/C Guy]

EDIT: Let me just reiterate this very important point...

The Everlast W300 cooler is a very nice unit for the money and it would be a serious challenge to build something as polished or "turn key" as that for $400. I really hesitate to encourage people to go down the path I went because it's a slippery slope and not really cheaper in the end (if time invested counts for anything). If you're a hardcore DIY type and enjoy this sort of thing, that's cool, but the only real advantage to my setup at this point is a pressure gauge and adjustable pressure regulator.

The most expensive part should be the trans cooler. The pump you picked is wrong, so you needed a relief valve. Grainger is the last place I shop for anything since they are usually double the price of most of my suppliers. A $24 cooler pump, coupled with a $50 trans cooler, plus some hose and a tank make a good set up for under $200. For a fan, get a fan used in a walk in cooler (like a keg cooler in a bar). Another option for a fan is a computer fan. With a power supply, a computer fan will cost under $30. Quiet and they have plenty of CFM for a TIG torch cooler.

[angular]

His cooler looks like an aftermarket transmission cooler. Try Autozone and O'Reilly auto parts.

That's correct and I already posted a link to it earlier in this thread.

The most expensive part should be the trans cooler. The pump you picked is wrong, so you needed a relief valve. Grainger is the last place I shop for anything since they are usually double the price of most of my suppliers. A $24 cooler pump, coupled with a $50 trans cooler, plus some hose and a tank make a good set up for under $200. For a fan, get a fan used in a walk in cooler (like a keg cooler in a bar). Another option for a fan is a computer fan. With a power supply, a computer fan will cost under $30. Quiet and they have plenty of CFM for a TIG torch cooler.

Right or wrong, the pump I picked is basically what many commerical TIG coolers use and a lot of guys on other welding forums recommended. It will run all day every day for many years. Some people have gotten away with running Procon carbonator pumps without an external relief valve, but in my testing this one couldn't go low enough.

I order from Grainger when it's convenient and the price on the item is acceptable. Their price on that pump motor was the same as every other online vendor and there was no shipping costs (just local sales tax).

Where exactly is this $24 pump you speak of? Honestly, how long do you think any $24 pump that can push 40-50 PSI is going to last in a TIG cooler application?

Finding and adding a 12V power supply that runs off of 230VAC just to run a fan is an added complication and expense that a lot people wouldn't be so keen on.

Have you actually built and used the DIY TIG cooler you describe for under $200? If so, post some pictures. Love to see it.

[geezer]

The most expensive part should be the trans cooler. The pump you picked is wrong, so you needed a relief valve. Grainger is the last place I shop for anything since they are usually double the price of most of my suppliers. A $24 cooler pump, coupled with a $50 trans cooler, plus some hose and a tank make a good set up for under $200. For a fan, get a fan used in a walk in cooler (like a keg cooler in a bar). Another option for a fan is a computer fan. With a power supply, a computer fan will cost under $30. Quiet and they have plenty of CFM for a TIG torch cooler.

Why waste your money on a Trans cooler, there must be a gazillion old fridges out there that have nice little radiators for that kinda thing. Salvage and reuse is the key to DIY projects