Guys, we need a challenge - welding respirator

[MeJasonT]

HSE is the UK have just decided that welding is finally dangerous for your health after years of saying the evidence was inconclusive.
They are bringing out new regulation regarding ventilation and controls to limit exposure to welding fumes.
As if by magic the £250 welding mask respirators have increased in value to £550.
The respirators that connect to air lines are the most bloody dangerous things you can think of, effectively you get drowned or worse. You have stale air in compressors which can have harmful H2S gas content, not exactly the alternative i would be looking for.
I have been playing around with the idea of 3D printing parts to attach a hose to the back of a welding mask and using the guts of a travel hair dryer (12v) powered from the guts of an old cordless drill to make a forced air system which would be mounted in a belt back behind the operator. Just like a real one. Cant get enough air pushed through. As it is a gotta have piece of kit we will all have on our wish list, I'm looking for us all to collaborate on a share alike open source design to come up with a cheap, reliable and easy to build alternative to the £1200 Miller equivalents.

Thoughts on the back of a cigarette packet please.

[Frank S]

I've been welding for over 50 years and can't ever remember breathing any fumes except when I had to weld inside of a vessel and then we had forced ventilation, for one I never have my head right over where I am welding and maintain a distance of at least 16 inches.
I've seen those dastardly Lincoln and Miller masks with the compressed air. you couldn't get me to wear one at any $$$$$ rate

[MeJasonT]

I hear what you are saying buddy.
Unfortunately it looks like this new enforcement is going to to affect all Uk welding operations, weather it be a self employed one man outfit or an engineering company. The idiotic government and its incompetent departments like to go balls out without thinking anything through. As if Loler and puwer were not enough on top of COSHH. They got rid of steel electrical consumer units when i was an apprentice as they were considered an issue when fighting electrical fires, the same idiots have now banned plastic in favour of steel again. what changed to make them safer and less of a risk, beats me - done both fire fighting and electrical work and can see why they were banned in the first place but not why they were brought back. You guys have a saying stupid is as stupid does, the Canadians have something about a bear.

I spent a sleepless hour last night (just one) thinking how i could build a compressor aka turbine engine with a 3D printer to push a higher volume of air.
There will be guys seeing dollar signs at the manufacturing opportunity of such an idea, id say don't do it. stay honest to the Homemadetools philosophy. No one stiffs you for metal brake plans - so share and share alike.

I will be photographing my current built parts + 3M ventilator mask (had an idea to do the thing either way, either a mask under the welding helmet or forcing air into the helmet without wearing a mask. Copyright shouldn't be an issue as SIP built one of these things in the 70s and have let their IP expire, i'm going to blame them.
Will also send current 3D part files for anyone interested.

[olderdan]

I have been wondering of late that most of these enforced new regulations are simply to generate VAT income for the government. The same has happened in the housing rental market as I have just been forced to spend close to £10 grand to allow me to rent one property, thats a lot of VAT @ 20%. they do not care if suppliers double their prices as they just get more. Tradesmen having to pay for enforced courses and update their equipment on a regular basis, we are on the 18th edition of electrical regs on a system that was already regarded as the safest in the world.

[mklotz]

I have been wondering of late that most of these enforced new regulations are simply to generate VAT income for the government. The same has happened in the housing rental market as I have just been forced to spend close to £10 grand to allow me to rent one property, thats a lot of VAT @ 20%. they do not care if suppliers double their prices as they just get more. Tradesmen having to pay for enforced courses and update their equipment on a regular basis, we are on the 18th edition of electrical regs on a system that was already regarded as the safest in the world.

Sometimes the regulations can get downright silly...

[Frank S]

The problem with respirators is they require a seal around the face. Anyone who has ever done much out of position welding in confined spaces has had an errant spark come bouncing around inside their mask. I've even had them get inside of leather sock hoods not fun when you have something making a seal around your face the spark will always find a fold to adhere to creating a painful burn. without a respirator that same spark may have struck your face but rolled harmlessly away while maybe creating a small irritating burn spot. Also those of us who sport a beard would tell the constabulary to go sod themselves.
I've been inside pressure vessels and tanks where it gets really hot and often times they are dusty respirators even forced air ones do not do much to alleviate the discomfort except for being able to breathe. What I usually did was merely attach a long hose to the exhaust of a clean shop-vac to the top inside of my hood not only could I breathe but it helped to reduce the buildup of heat in my hood.
We were replacing the klinker chains in a cement kiln once the kiln was still 140°f inside piping forced cooling only served to create a thick dust cloud so we used air hoses from a large air compressor with a charcoal scrubber filter the air was close to dive tank quality which turned out to be a better solution than having us try to wear underwater type welding helmets too cumbersome and heavy when you are not in water.
So your idea or a personal waist pack with a turbine fan ducted through a hose to your helmet is a good one you will want to add a rear cover to fully engulf your head to insure the air flow has a positive pressure forcing the air down past your neck and shoulders.

[metric_taper]

This wheel has already been invented.
https://www.millerwelds.com/safety/r...irators-m00482
But $2000USD it's pricey.
This was the first hit on search for "welding helmet with air filtration", so there probably are many other suppliers.
3M has one titled FRESH AIR WELDING HELMET SYSTEM, which used compressed air with a vortex tube, similar to mining equipment. But it's ~$1600USD.
I've looked for this before, but just for cooling air, as I get's real irritated when my eye glasses, and the shade glass fog up.

[Frank S]

Yeah who are they going to fine the dead guy who touched the wires or the surviving family who knew nothing of his intentions to touch them

[Tuomas]

This wheel has already been invented.
https://www.millerwelds.com/safety/r...irators-m00482
But $2000USD it's pricey.
This was the first hit on search for "welding helmet with air filtration", so there probably are many other suppliers.
3M has one titled FRESH AIR WELDING HELMET SYSTEM, which used compressed air with a vortex tube, similar to mining equipment. But it's ~$1600USD.
I've looked for this before, but just for cooling air, as I get's real irritated when my eye glasses, and the shade glass fog up.

3M has also "Adflo" battery operated system to be used with Speedglas masks & helmets.
https://www.3m.com/3M/en_US/speedgla...mets-us/adflo/

I have used them 10 years. Now i have 9100 fx model.
Battery lasts 8 hours continous use. Filters about month to two in daily 8h welding. Helmet has seals and blower keeps positive pressure inside it, keeping dust out.

Here those are about 500$ each.

That compressed air purifier is great too, air temperature can be adjusted between cool to warmish ( with friction heater) Great option specially in hot weather.

I have used that when welding inside containers etc.
Big minus is, that you need to change filters regularly ( monthly) , even if you haven't used it very much.

I don't know why, moisture, oil or something makes it great for bacterial culture.. and when used with too old filters you get atleast a flu or infection. I have got nasty flu from it couple times, that is a good reminder.

Bonus is that three welders can use same filter, if compressor is big enough.

I have used Racal, Esab and 3M respiration systems during my 20 years in welding. 3M adflo has been most reliable, comfortable and cheapest to use.

Idea about making respirator is good, it shouldn't be difficult.
I think it should be based to use " Third party " filters.
Batteries, 3D printed casing, and a small radial blower..

[Frank S]

I would almost guarantee there is a paper trail leading to lobby money every time these new ever more restrictive laws are proposed