New Frame for Everlast Welder

[Don52]

One of my good customers likes to design heavy Aluminum fabrications that are beyond the capability of my 200-amp Dynasty welder. I really hate to turn down good work, so I purchased a water cooled 400-amp Everlast PowerTIG 400EXT welder to enable me to weld thicker Aluminum. I considered a Dynasty 400DX, but the $16k price encouraged me to buy the $4k Everlast welder instead. I purchased the Everlast cart with the welder and I fabricated a frame to mount on top of the cart. I purchased a drawer assembly and a sheet metal foot pedal holder from ZT Fab. I also bought a few 3” round disks from a company on the internet. Below is an exploded view of a model of the welder with the new frame and the new drawer assembly.

1. New frame for Everlast welder


The first step was to cut out all of the required pieces. The rectangular tubing came from an old bed frame.

2. Pieces cut out


3. Cable Holder


I welded the 3” disks to a piece of 7/8” tubing to make the cable holders.

4. Frame fixtured for welding


I used my Fireball squares to hold the frame together for welding

5. First weld

[Don52]

6. Second weld


7. Third weld


8. Fourth weld


9. All welded and painted


10. Frame mounted

[Don52]

11. Drawer mounted left side


12. Drawer mounted right side


13. Drawer mounted right side close up


I intend to use the drawer for extra torches and other stuff that goes with this welder.

-Don

[ryanjones2150]

Hey! Are those my fireball squares?! I thought you said I could have them?

Nice cart/drawer holder thing.

400 amps? I bet that torch gets hot. You add and helium in there?

[Don52]

Hey! Are those my fireball squares?! I thought you said I could have them?

I really like the Fireball squares and use them on almost every project.

Nice cart/drawer holder thing.

Thanks

400 amps? I bet that torch gets hot. You add and helium in there?

I bought this welder to weld thick Aluminum at high amperage. The torch that came with it was only rated for 250 amps on AC. I purchased a new 350 amp CK Worldwide torch, but I haven’t hooked it up yet. The water cooler should keep the torch from getting too hot. This welder has a mode that switches from AC to DC, which is designed for welding thick Aluminum. A lot of welders in Europe apparently have this feature. This feature can add up to 30% more heat. I still have cylinders of 25% He 75% Ar, which I can use if necessary, but would like to try out this new feature first.

-Don

[ryanjones2150]

Sounds like a pretty cool feature, I’m interested to hear how it goes.

[aametalmaster]

Nice