DIY Tig Torch cooler

Robert Hall · Jul 26, 2014

So in the vein of why buy when you can make it yourself she's finally finished.

Some specs...

3.5 gallon 16 guage stainless tank
45 psi shureflow pump 12v. #8005-292-139
125cfm fan. 12v and way overkill. But it's what I had.
850 watt computer power supply. Again, what I had.
9x12 aux radiator from ebay. $50.
16x24 aluminium base. 12 gauge.

Finished product:

Kind of the business side..

Closeup of the stainless screws in the aluminum base. .

Setup for the switch panel...

Tbc...

Robert Hall · Jul 26, 2014

A few more pics. ..

Fan assembly

I was stuck with the compression firing so I tapped the id to fit a quarter inch pipe fitting

Dark pic, sorry. Streampunk look continuing through the build

Better image...

Robert Hall · Jul 26, 2014

Fan Box build

rsanter · Jul 26, 2014

Very nice
Now if it was me I would build a rolling frame around it with a top and use it as a welding table

Bob

Robert Hall · Jul 26, 2014

Base build. 12 gauge aluminum

Rails

Robert Hall · Jul 26, 2014

It belongs here...

I'm going to swap the saw for the cooler. That was the idea at least.

AussieDan · Jul 27, 2014

Nice work!

Gizmosity · Jul 27, 2014

Awesome! Filing this away for when I actually get TIG capability in my shop.

Couple questions though:

Pump. Fan. What's the third switch for?

(I just realized you must have bypassed the switch on the power supply.)

What are you using to score your material that accurately (straight and consistent depth) prior to bending?

AussieDan · Jul 27, 2014

I'd guess the power supply, you connect a switch between pin 14 (green) and ground to turn the PSU on and off.

Robert Hall · Jul 27, 2014

AussieDan said:
Nice work!

Thanks AussieDan!

Yes. Did the bypass with the Green!

Robert Hall · Jul 27, 2014

Gizmosity said:
Awesome! Filing this away for when I actually get TIG capability in my shop.

Couple questions though:

Pump. Fan. What's the third switch for?

(I just realized you must have bypassed the switch on the power supply.)

What are you using to score your material that accurately (straight and consistent depth) prior to bending?

Yes! Bypassed.

I used a table saw on all the aluminum. Cut about 60% through. Very Strong with one bend, but that's all you get. Used a sheer on the stainless.

Thanks!

HOTFR8 · Jul 27, 2014

Nicely done.

hippie2cams · Jul 28, 2014

the screws weren't clocked :lol_hitti

Robert Hall · Jul 28, 2014

hippie2cams said:
the screws weren't clocked

One must draw a line on their level of ****.

Robert Hall · Jul 28, 2014

HOTFR8 said:
Nicely done.

Thank you!

91bronc300 · Jul 28, 2014

Where'd you find your copper heat sink at?

Robert Hall · Jul 28, 2014

91bronc300 said:
Where'd you find your copper heat sink at?

Local metal supply. Kind of a steal.

nine4gmc · Jul 28, 2014

newbie question here, I just got a used Hobart Tigmate 165(I think) with a Miller torch. Would it work with a DIY cooler like this?

Robert Hall · Jul 28, 2014

nine4gmc said:
newbie question here, I just got a used Hobart Tigmate 165(I think) with a Miller torch. Would it work with a DIY cooler like this?

The hardest thing I had to do was to find brass fittings for all this.

There are things to consider, such as what pressure can your hose take, can you find a pump that matches that, etc.

For this project one also needed to be able to weld aluminum and stainless.

Im hardly the first to do this. In fact I like that others have found issues with the builds as well. To them I send my thanks.

nine4gmc · Jul 28, 2014

Thanks Robert, your cooler looks great!

zkling · Jul 28, 2014

nine4gmc said:
newbie question here, I just got a used Hobart Tigmate 165(I think) with a Miller torch. Would it work with a DIY cooler like this?

Yes, but i don't think it would be a worth while investment. The limited duty cycle on that machine is like a built in torch cooler. I primarily use a WP17 air cooled till I get up above the 175+amp range, and I'm running a machine that will do 100% duty cycle at 150amp, yours is down in the 20% range at the same amperage. Just my 2 cents. :beer:

Good job Robert :thumbup:

dr_clyde · Jul 29, 2014

Most welding supply houses would carry all the brass fittings and hoses for a DIY cooler.

Robert Hall · Jul 29, 2014

True, but most at my lws are for gas not liquid. It took me 3 supply houses to find mine. But then brass is not my specialty.

Robert Hall · Jul 29, 2014

zkling said:
Yes, but i don't think it would be a worth while investment. The limited duty cycle on that machine is like a built in torch cooler. I primarily use a WP17 air cooled till I get up above the 175+amp range, and I'm running a machine that will do 100% duty cycle at 150amp, yours is down in the 20% range at the same amperage. Just my 2 cents.

Good job Robert

Thanks!

And you make a good point.

hippie2cams · Jul 30, 2014

Sorry about the screw clocking comment in a previous post but I couldn't find anything else wrong. I was just wondering why not just buy a water cooled high frequency machine instead.

Robert Hall · Jul 30, 2014

hippie2cams said:
Sorry about the screw clocking comment in a previous post but I couldn't find anything else wrong. I was just wondering why not just buy a water cooled high frequency machine instead.

I thought it was quite amusing.

As to why build when you can buy, it saved me close to $1000 doing it myself. Most of the time I only need a 150 amp air cooled torch, but I have a job that requires a lot more on a few parts. I figured it would not be economical to buy all this for the occasional need.

Ok, that and I like the look of mine infinitely better than the factory made.

Guster · Jul 30, 2014

I'll second your sentiment that I have a need but not enough to justify investing in a commercial capability for very intermittent use. Hence why I have also been collecting bits like a second hand water cooled torch, carbonator pump and small intercooler radiator in a cost effective manner. Even scored a small fan to stick on the other side of the pump motor to draw air over the radiator which will work out quite nicely.

All I need to complete mine is a reservoir, frame to mount it all and and make a nice enclosure to duct the airflow effectively.

Robert Hall · Jul 30, 2014

If I was a thinking man I would have designed it to blow over the pump as well.

Guster · Jul 30, 2014

Hehe... already thunk it that way too. Though I have not checked the fan pitch to the motor direction. I could always make something like a little auto radiator fan if needed.

May also have a free lead on a small but deep stainless steam pan ie. what they serve food in at buffet setups that would make a great little reservoir. Not above making something but time is money too.

Hornman · Jul 30, 2014

Steampunk Kokopelli! I belive you have created a new category. Nice cooler project by the way.

dogdog · Jul 30, 2014

how did you etch that graphic to the tank or is it a sticker?

Nice project.

Capt Chrysler · Jul 30, 2014

Stupid question! The computer power supply will have the needed amps to run the pump & fan?

Sorry I have never worked with that power supply. :dunno:

Capt. Chrysler

Robert Hall · Aug 1, 2014

Thanks, hornman!

Robert Hall · Aug 1, 2014

dogdog said:
how did you etch that graphic to the tank or is it a sticker?

Nice project.

I used a laser printer. Hahahah

Ok is a laser that cuts Plastic and etches steel. About 70 watts.

And thank you.

Robert Hall · Aug 1, 2014

Capt Chrysler said:
Stupid question! The computer power supply will have the needed amps to run the pump & fan?

Sorry I have never worked with that power supply.

Capt. Chrysler

Yes. It is something to consider.

12v fan at 3 amps. P=IE so 12x3=36 watts.

12v pump at 2.6amps about 30 watts.

Power bulbs. 100mw for a total of 66.3 watts. 850 watt power supply using 5.9 amps of 65 amps available means I cold power a small city with what is left over.

Robert Hall · Aug 1, 2014

It was suggested by a colleague that I add a vibe absorber tube.

It works well and the wife really thinks it's cool. Whatever. As long as she's happy.

Vid below too.

MN4x4 · Nov 30, 2014

So here's my stupid question being new to TIG - what are the three switches for?

Based on your components I'd guess Pump /Fan / and ?

But I could be all wrong...

toms73novass · Nov 30, 2014

power supply

vpd66 · Nov 30, 2014

Nice job on the cooler. I have an old Airco Heliarc 250 ac/dc (Miller Dialarc clone) and it came with a cooler and all it has is a 4 gallon tank with the pump mounted on top of it. I've welded 3/8" aluminum with it and the water in the tank never got hot. Yours is definitely overkill.

shawnspeed · Nov 30, 2014

I also built my own ...20 odd years ago. I was fortunate enough to find the remnants of a syncro 300 cooler that was just a large tank under the welder. I scavenged the pump , which I re-built, the sight glass, and the coolant distribution block. I built a 2-2.5 gal stainless tank , and bought a motor to power the pump, and then I had an un used trans cooler that I hang over the back of my welder in front of the fan. The fan on my old syncro 250 is on all the time, so no need for an extra fan....I have never over heated the torch , and have had some pretty good sessions with some thick aluminum castings...The OP 's cooler looks like it should work perfect...Shawn

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