Miller Thunderbolt 225

[Jeep Monkey RTR]

Brought my wife's grandfathers stick welder home this weekend. He passed away about 15 years ago and it has been sitting unused in his warehouse since.

I am in the process of learning how to weld (mig) but thought it would be cool to make use of his stick welder since it can be had for free.

A couple of things:
- it needs new leads (dry rotted)

- it needs a new power supply cord (dry rotted).

- probably needs to be torn apart to clean.

This will be my first time delving into a welder. Any tips or suggestions on what I should expect and plan to do along the way?

Sent from my iPhone using Tapatalk

 

[astrotrain99]

Don't have your answers but I am almost in the exact same situation with the same model welder!

 

[c39er]

I learned to stick weld on one of those back in the late sixties early 70's!
Go online and looks at guys showing you how to stick weld.
You also might go to the welders store and pick up a stick welders welding guide and practice, practice, and practice more use 6010 or 6011 to start.

Correction as mentioned below 6010 DC RP only--my bad!

 

[RandyL]

Looks like someone is stealing your bottle of hooch ( right side, last pic ).. Might want to look under table, he may be passed out.

Randy

 

[tyjoja]

milller website has a good tutorial on how to weld. It will also give you maintenance tips. I bought a little newer miller used and tore the cover off and blew it all out with air and cleaned it and greased the screw thread that moves the transformer up and down when you adjust the amperage.

 

[sprntpshr]

I have had a couple of them thru the years. Check to see if the cooling fan runs, had one seize up. Used a fan from a kitchen hood to replace it. Careful with the fan voltage rating, the welder may use a 220v fan, kitchen fan 120v.

Turn the handle on the top, make sure the transformer core moves freely. While it is apart clean up the 3 cable contacts on the front, had one of those burn up due to dirty/corroded.

My current Thunderbolt is a AC/DC version, made up a cart for it and will post a picture tomorrow. It runs 7018, 6011, 6013 rod depending what I am welding.

 

[wnstwolf]

Don't get sticker shock when you go purchase new leads. Get them as long as you cn afford. I found Tractor Supply or if you have a connection wih a contractor that can get wire at wholesale is best route.

Power cord not so bad.. I have an old Lincoln tombstone that I ued all the time to make a big mess with until I got the knack of how to really use thething. Then got a Millermatic MIG and wow tough to ever go back... Know why they are called tombstons now

 

[Jeep Monkey RTR]

Looks like someone is stealing your bottle of hooch ( right side, last pic ).. Might want to look under table, he may be passed out.

Randy

Your post owned me. My son has an unhealthy obsession with spray bottles. I just cant keep that little Leprechaun away from the stuff.

 

[Jeep Monkey RTR]

I have had a couple of them thru the years. Check to see if the cooling fan runs, had one seize up. Used a fan from a kitchen hood to replace it. Careful with the fan voltage rating, the welder may use a 220v fan, kitchen fan 120v.

Turn the handle on the top, make sure the transformer core moves freely. While it is apart clean up the 3 cable contacts on the front, had one of those burn up due to dirty/corroded.

My current Thunderbolt is a AC/DC version, made up a cart for it and will post a picture tomorrow. It runs 7018, 6011, 6013 rod depending what I am welding.

Please do post up a pic. I cant wait to see yours.

What do you consider "turning freely" regarding the handle on top? Mine turns but there is noticeable resistance.

I will be sure to clean the cable contacts. When I pulled the welder from the warehouse, one of the connectors had been previously occupied by a dirt dauber

 

[Jeep Monkey RTR]

Don't get sticker shock when you go purchase new leads. Get them as long as you cn afford. I found Tractor Supply or if you have a connection wih a contractor that can get wire at wholesale is best route.

Power cord not so bad.. I have an old Lincoln tombstone that I ued all the time to make a big mess with until I got the knack of how to really use thething. Then got a Millermatic MIG and wow tough to ever go back... Know why they are called tombstons now

I definitely plan to get a MIG machine sooner rather than later. That is what I have been learning on and MAN, they are easy. What model Miller did you get?


Thanks for the tip on the leads. I will do my best not to faint from the shock.

 

[sprntpshr]

Here is a couple of pictures of my Thunderbolt, had it 20 years now. About 5 years ago, built a cart for it to be a little more mobile in the old shop.

The current selector handle should turn with a little resistance like a window crank on a car door. Sounds like you are on the right track.

 

[wnstwolf]

I have the Millermatic 210 it's about 10 years old and came with the spool gun for alum. It was the model before the digital display came out and this one was still on the floor. With wire and some other consumables I was out the door for $1,500 new. Sad thing is it took me about 3 years to ever need to use the spool gun. That thing rocks. I want to build everything out of alum now! Aside from my 2 post lift and the Kubota the 210 is one of the best tools in the garage!

 

[Ajustable]

I started welding using a linde stick welder, It had been through a garage fire, so we had it tested and they said it wasn't damaged. I have been welding with it for 30 years now. A stick welder is great for so many weld jobs. you'll love it.

I started with 6011 and 6010 rod, but I had so much trouble with starting the weld, the weld supplier suggested a rod some times called "rust rod", I figured that is appropriate cause I was welding old rusted metal quite often, doing repairs. Try 7014 if your having trouble, splatters quite a bit and the scale is fairly heavy, but cleans up well if the bead is layed down well.

 

[Vegaman_Dan]

I just went through a 225 recently with a rebuild and maintenance. The interior was very dirty so I spent some time cleaning the unit, especially the cooling fan and blades. The core slides back and forth through the transformer windings using a center crank / worm gear. Mine was caked with grime and dirt, so I unbolted and removed the blocks on the sides of the slide, cleaned everything and hit it with enough penetrating oil until the slide worked again. Cleaned up all that mess, then hit it with plastic safe silicone grease.

The center actuating rod would bunch up and click while turning. I found the set screws were loose at the center allowing it to slip. You can access them by looking down through the windings and with a long allen wrench, tighten them up. It slides much more smoothly now.

General cleanup was all that was really necessary. There's not much inside these units that can go wrong. Getting leads made was the most expensive part, and you can buy those on Amazon if you wish. I had some really nice ones made up so I could use them on another welder later if I decided to go that route.

 

[Kingcreek]

Download the owners manual from the miller website. Clean, lube, and enjoy!
I've got an AC/DC model from 1993, works great and does most anything I need.

 

[John in OH]

I learned to stick weld on one of those back in the late sixties early 70's!
Go online and looks aguys showing you how to stick weld.
You also might go to the welders store and pick up a sticke welders welding guide and practice, practice, and practice more use 6010 or 6011 to start.

Just a heads-up that you probably already know, but your welder is an AC only unit and won't run the 6010 rod as it is for DC only. The 6010 and 6011 are very similar welding rods with similar arc characteristics and applications, but the 6011 was developed specifically for AC welders.

You may also want to read through a recent GJ thread on a similar Thunderbolt topic: http://www.garagejournal.com/forum/showthread.php?t=243760&highlight=thunderbolt

 

[RandyL]

I just went through a 225 recently with a rebuild and maintenance. The interior was very dirty so I spent some time cleaning the unit, especially the cooling fan and blades. The core slides back and forth through the transformer windings using a center crank / worm gear. Mine was caked with grime and dirt, so I unbolted and removed the blocks on the sides of the slide, cleaned everything and hit it with enough penetrating oil until the slide worked again. Cleaned up all that mess, then hit it with plastic safe silicone grease.

The center actuating rod would bunch up and click while turning. I found the set screws were loose at the center allowing it to slip. You can access them by looking down through the windings and with a long allen wrench, tighten them up. It slides much more smoothly now.

General cleanup was all that was really necessary. There's not much inside these units that can go wrong. Getting leads made was the most expensive part, and you can buy those on Amazon if you wish. I had some really nice ones made up so I could use them on another welder later if I decided to go that route.

That is the model I have...the lay down version. I had two and gave one away some 20 years ago..figured I'd never wear them out, and I have not!
Just got new concrete in the shop so things will move much easier now. I stopped at Harbor Freight 2 days ago and paid $7 for a little, wood, rectangle, furniture mover that has 4 casters... I set my stick weld on it and it looks like the cart has made for it, perfect fit!! Most of my welding is MIG, but I love burning up some sticks on large projects.

 

[RandyL]

I had to run out and take a quick pic of the furniture moving cart. Things are in disaray and dirty after the move for new concrete..but I'm getting there!

 

[RandyL]

Just a heads-up that you probably already know, but your welder is an AC only unit and won't run the 6010 rod as it is for DC only. The 6010 and 6011 are very similar welding rods with similar arc characteristics and applications, but the 6011 was developed specifically for AC welders.

You may also want to read through a recent GJ thread on a similar Thunderbolt topic: http://www.garagejournal.com/forum/showthread.php?t=243760&highlight=thunderbolt

Where does 6013 fit in??

 

[RedneckWelder]

Where does 6013 fit in??

Lower penetration, good for thinner metal. Not really a fan of it myself. If you can find it in 1/16" dia you can use it on sheetmetal (not the easiest to run, mind you, but in a pinch...). I keep a little on hand but never really seem to use it. It's OK for general repairs.

6010 and 6011 are deep penetrating fast freeze rods. Great for filling gaps and burning through paint/rust. 6011 is for AC machines, 6010 is DC only.

7018 is a high strength rod that produces really nice beads and is a really good all around rod. You'll have to use 7018AC with your AC welder.

7018 and 6010/6011 are probably the most popular rods all around. Keep both on hand and you'll be covered.

 

[mr overdunne]

It's really hard to beat those old machines for the money.