How to build a DIY spot welder for 1mm aluminum sheet?

Hi everyone, I'm trying to build a DIY spot welder (spotter) to work with thin aluminum sheets, around 1mm thick. I know that welding aluminum is more difficult than steel due to its conductivity and oxide layer, so I have a few questions: What kind of power supply or transformer would be suitable? What electrodes/tips are recommended for aluminum? Any specific timing or pressure needed to avoid burning through? Has anyone built something similar and can share experience or diagrams? Any help, recommendations, or even links to builds would be really appreciated. Thanks in advance! submitted by /u/nmegabyte [link] [comments]

May 4, 2025 - 18:16
 0

Hi everyone,
I'm trying to build a DIY spot welder (spotter) to work with thin aluminum sheets, around 1mm thick.
I know that welding aluminum is more difficult than steel due to its conductivity and oxide layer, so I have a few questions:

  • What kind of power supply or transformer would be suitable?
  • What electrodes/tips are recommended for aluminum?
  • Any specific timing or pressure needed to avoid burning through?
  • Has anyone built something similar and can share experience or diagrams?

Any help, recommendations, or even links to builds would be really appreciated. Thanks in advance!

submitted by /u/nmegabyte
[link] [comments]