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New Frame for Everlast Welder

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  • New Frame for Everlast Welder

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

    4. Frame fixtured for welding
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    I used my Fireball squares to hold the frame together for welding

    5. First weld
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    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Lincoln LE 31 MP
    Lincoln 210 MP
    Clausing/Colchester 15" Lathe
    16" DoAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport

  • #2
    6. Second weld
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    7. Third weld
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    8. Fourth weld
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    9. All welded and painted
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    10. Frame mounted
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    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Lincoln LE 31 MP
    Lincoln 210 MP
    Clausing/Colchester 15" Lathe
    16" DoAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport

    Comment


    • #3
      11. Drawer mounted left side
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      12. Drawer mounted right side
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      13. Drawer mounted right side close up
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      I intend to use the drawer for extra torches and other stuff that goes with this welder.

      -Don
      Smith Oxyacetylene Torch
      Miller Dynasty 200DX
      Lincoln SP-250 MIG Welder
      Lincoln LE 31 MP
      Lincoln 210 MP
      Clausing/Colchester 15" Lathe
      16" DoAll Saw
      15" Drill Press
      7" x 9" Swivel Head Horizontal Band Saw
      20 Ton Arbor Press
      Bridgeport

      Comment


      • #4
        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?

        Comment


        • #5
          Originally posted by ryanjones2150 View Post
          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
          Smith Oxyacetylene Torch
          Miller Dynasty 200DX
          Lincoln SP-250 MIG Welder
          Lincoln LE 31 MP
          Lincoln 210 MP
          Clausing/Colchester 15" Lathe
          16" DoAll Saw
          15" Drill Press
          7" x 9" Swivel Head Horizontal Band Saw
          20 Ton Arbor Press
          Bridgeport

          Comment


          • #6
            Sounds like a pretty cool feature, I’m interested to hear how it goes.

            Comment


            • #7
              Nice
              Bob Wright

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