Welder Upgrade

I’ve owned a Lincoln Weldpack 100 for some time now. Since day 1 I have always wished it could be a MIG welder. Inner shield is cheap and can make good welds. But comes at a price. It’s basically stick welding, so it’s messy. But if you do it right the slag falls off and a shiny weld is what’s underneath. Then you spend the next 10 minutes cleaning off you part. No longer! 

A peak under the hood of my welder reveals a 115v solenoid! I found this key complement on Amazon for $14.

My $14 solenoid valve with air fittings attached.

Parts list:

110v 60hz gas solenoid – Amazon, $14

1/4″ clear tube – Lowes about $1

1/4 bard x 1/4NPT – Lowes $5

1/4 NPT Brass street elbow – Lowes $5

1/4″ spade crimp connectors – free from my spare parts stock

Tiny hose clamps – free from spare parts stock

0.030″ contact tip – internet 12pack $5

1/2″ Gas nozzle –  internet $2

Screws for gas solenoid – free spare stock

CO2 regulator – Harbor Freight $27, this one sucked. Get it from Amazon for less and buy the adapter

I started by crimping my spade connectors to the solenoid. Then I used a paper to make a rubbing of the mounting bolt pattern on the solenoid.

I used a center punch to transfer than to the back of the welder case.

After the holes were drilled, I dug around in my spare bolts for 2 that fit and attached the solenoid. I then marked and drilled the hole for the gas inlet with a step drill.

I attached the spade connectors to the control board and hooked up the gas in and out lines. I also had to reverse the positive and ground leads to the gun. 

Hooked up the regulator and replace the wire, contact tip and gas nozzle. Done. 

Start of the build

We purchased a Sleep Number bed for Black Friday (absolutely hate it). This meant a new project, a bed frame. My wife is an absolute lover of all things Modern, black walnut and brass. I decided to try and incorporate all these and made a design sketch.

The original head board was just behind the bed, but Joey asked that it extend behind the night stands and that the night stands float on it. That made the total width just under 10ft. I found a 10ft long black walnut veneer at oakwoodveneer.com and they were able to ship it out the same day.

I built the headboard out of 3/4 sanded plywood with a 2×4 frame.

The plane was to inlay a 1″ wide brass strip between the edge and veneer so I put the veneer on before installing the edge. Above the assembled, bondoed and sanded head is stood upright. This allowed me to position the extra long piece of veneer by myself. Beachside of the angle that the board sits at it left a gap at the bottom for the bottom overhang. This was accidental, but it worked out well.

The headboard back up on the saw horses. It was actually a bit longer than I needed (not sure how that happened), so I trimmed the end to give me a 7/8″ spacing between the 3/4″ wide walnut edge and the veneer. After the edge strip was attached, I used a scrap piece of my brass and a razor blade to trim the veneer to the exact width. I then cut my brass strips and glued them in with PVA glue I had leftover from my piano restoration.

Headboard, footboard and sides laid out for test fitting. Note the 1″ width exposed wood on the headboard. This is where I would later put the brass inlay.

Bolted together in final position. I toe screwed the 2×4 stringers in place and then screwed down 3/4″ sanded ply on top for the deck. I drilled pass-through holes where the night stands will later attach.