Free 173 Best Homemade Tools eBook:  
Remove advertisements
Results 1 to 9 of 9

Thread: 500 Amp Welding machine rebuild

  1. #1
    Frank S's Avatar
    Join Date
    Aug 2015
    Location
    Peacock TX
    Posts
    2,480
    Thanks
    452
    Thanked 2,231 Times in 1,094 Posts

    Frank S's Tools

    500 Amp Welding machine rebuild

    It's been a while since I did this on ebut I thought I would share.
    This is a 500 Amp Miller Air pac with a 12 KW 3 ph option it was in pretty sad shape after being used by the railroad for many years, but it still ran and all systems functioned as they should so that made it worth rebuilding
    500 Amp Welding machine rebuild-miller1.jpg
    500 Amp Welding machine rebuild-miller-2.jpg
    500 Amp Welding machine rebuild-miller-3.jpg
    500 Amp Welding machine rebuild-miller-4.jpg
    500 Amp Welding machine rebuild-miller-5.jpg
    500 Amp Welding machine rebuild-miller-6.jpg
    Railroad track Forming anvil die I welded a strip of flat bar to one side of the rr track so I could have a different forming anvil shape for straightening the top and side covers
    500 Amp Welding machine rebuild-railroad-track-forming-die.jpg
    500 Amp Welding machine rebuild-miller-7.jpg
    Some covers were missing so I had to hand make them
    500 Amp Welding machine rebuild-miller-8.jpg
    Laying out for perforation punching
    500 Amp Welding machine rebuild-miller-9.jpg
    Using my Roper Whitney 8 ton manual punch with a special ground die to make the oval perforations the Die and punch were bought from Cincinnati punch works
    500 Amp Welding machine rebuild-miller-10.jpg
    500 Amp Welding machine rebuild-miller-11.jpg
    Splash on a little paint and good as new. Almost impossible to tel which panels were straightened and which were hand made
    500 Amp Welding machine rebuild-miller-12.jpg
    500 Amp Welding machine rebuild-miller-13.jpg
    500 Amp Welding machine rebuild-miller-14.jpg
    add a few decals and that is how you take a $800.00 salvaged machine to being sold for $15,000.00
    500 Amp Welding machine rebuild-miller-15.jpg
    Last edited by Frank S; 10-12-2017 at 12:27 PM.
    Never try to tell me it can't be done
    When I have to paint I use http://kbs.justoldtrucks.com/

  2. The Following 7 Users Say Thank You to Frank S For This Useful Post:

    DIYer (10-14-2017), Jon (10-12-2017), PJs (07-22-2018), Rancher (10-31-2017), rlm98253 (07-20-2018), Seedtick (10-12-2017), thevillageinn (10-22-2017)

  3. #2
    rendoman's Avatar
    Join Date
    Nov 2015
    Location
    Italy
    Posts
    314
    Thanks
    382
    Thanked 336 Times in 179 Posts

    rendoman's Tools
    Nice done!
    This welder is huge!

  4. #3
    Frank S's Avatar
    Join Date
    Aug 2015
    Location
    Peacock TX
    Posts
    2,480
    Thanks
    452
    Thanked 2,231 Times in 1,094 Posts

    Frank S's Tools
    Quote Originally Posted by rendoman View Post
    Nice done!
    This welder is huge!
    Thank you .
    Yes it is the engine is a 68 HP 4 cylinder air cooled Deutch the #1 cylinder has an air compressor head on it to the tune of something like 46 CFM @90 PSI
    The welder will burn 1/2" gouge carbons all day long and not complain and the 46 CFM air will blow the slag 20 feet. I rebuilt it for a customer who turned down the $15,000.00 offer. I know this for a fact because I am the one who offered that amount after he had paid me to restore it
    He uses it every day to power his truck repair shop. He says they can run all of the shop electrical requirements off of the regular 110/220 receptacles even while welding using 3/16 or even 1/4" rods or when he needs to use the 3ph he still has the 110/220 Plus the air to run impacts or for tire repair
    Never try to tell me it can't be done
    When I have to paint I use http://kbs.justoldtrucks.com/

  5. #4
    Content Editor DIYer's Avatar
    Join Date
    Aug 2013
    Posts
    3,087
    Thanks
    334
    Thanked 639 Times in 580 Posts


    Thanks Frank S! We've added your Welding Machine Rebuild to our Welding category,
    as well as to your builder page: Frank S's Homemade Tools. Your receipt:




  6. #5
    Content Editor DIYer's Avatar
    Join Date
    Aug 2013
    Posts
    3,087
    Thanks
    334
    Thanked 639 Times in 580 Posts


    Thanks Frank S! We've added your Anvil Die to our Anvils category,
    as well as to your builder page: Frank S's Homemade Tools. Your receipt:




  7. #6

    Join Date
    Jul 2016
    Posts
    99
    Thanks
    31
    Thanked 20 Times in 19 Posts
    Fantastic! Go big or go home as they say. Work like that takes real skill!
    Eric
    👍

  8. The Following User Says Thank You to suther51 For This Useful Post:

    Frank S (03-21-2018)

  9. #7

    Join Date
    Feb 2015
    Posts
    60
    Thanks
    0
    Thanked 8 Times in 7 Posts
    So that was pretty much cosmetic? How much would it be worth without the new paint? I'd love to have that machine, especially for $800 bucks.

  10. #8
    Frank S's Avatar
    Join Date
    Aug 2015
    Location
    Peacock TX
    Posts
    2,480
    Thanks
    452
    Thanked 2,231 Times in 1,094 Posts

    Frank S's Tools
    Quote Originally Posted by Pa1963 View Post
    So that was pretty much cosmetic? How much would it be worth without the new paint? I'd love to have that machine, especially for $800 bucks.
    Not entirely cosmetic the way those machines are made their cooling depends a lot on the sheet metal matching up to the internal ducts plus you have to remove most of the sheet metal just to get to any internal components to tighten any loose connections or anything else trying to reinstall bent up sheet metal can take as long as it would to just straighten it up some. But to answer your question I doubt if a running machine that size with the options installed could be bought for less than 5 grand even as bent up as it was.
    My customer buys a lot of auction equipment and has often said that he can buy for 10 to 20 cents on the dollar of a machine's worth. I told him that I would pay $2000,00 for every complete large machine like that one that he can buy for a $1000.00 so far I haven't had to cash any CD's to back up my loud mouth, but I'm sure the day will come. I did buy a Miller Bobcat 225 at auction for $275.00 that wasn't running it had only 400 hours on the meter and was 5 years old I spent about 75 to replace missing parts repaired 3 broken head bolts but didn't bother with cosmetic work. I've now got about 700 hrs on it but wouldn't sell it for less than $2,500.00
    Last edited by Frank S; 03-22-2018 at 05:06 PM.
    Never try to tell me it can't be done
    When I have to paint I use http://kbs.justoldtrucks.com/

  11. #9
    Savage11's Avatar
    Join Date
    Feb 2018
    Location
    Amish Country Ohio
    Posts
    50
    Thanks
    8
    Thanked 47 Times in 16 Posts

    Savage11's Tools
    You are a genius man. That is awesome. I would live to find a welder generator at those prices. Your work is mind blowing!!


    Post your reply!
    Join 33,912 of us and get our 173 Must Read Homemade Tools eBook free.



    173 Must Read Homemade Tools

Thread Information

Users Browsing this Thread

There are currently 1 users browsing this thread. (0 members and 1 guests)

Bookmarks

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •