Building a TIG water cooler can be a rewarding project for welders who want to improve their welding capabilities, especially when working with aluminum. This comprehensive guide will provide you with a detailed, step-by-step process on how to build a TIG water cooler, along with technical specifications and a hands-on DIY approach.
Components and Materials
To build a TIG water cooler, you’ll need the following components and materials:
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Tig Quick Connectors: These connectors allow for easy and secure attachment of the water cooling system to your TIG torch. Look for high-quality, durable connectors that can withstand the pressure and temperature of the cooling system.
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Carbonator Pump Motor: This type of pump is commonly used in soda dispensers and provides the necessary water flow for the cooling system. Opt for a 230-volt, 1/3 hp electric motor with a speed of around 1725 rpm.
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Procon Brass Pump: The Procon brass pump is a reliable and efficient choice for the water circulation in your TIG water cooler. It can handle the required pressure and flow rate.
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Pump Mounting Clamp: This clamp will securely hold the Procon pump in place within the cooler’s frame.
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Bleed-Off Needle Valve: This valve allows you to adjust the pressure in the cooling system, ensuring optimal performance.
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Mesh Inline Filter: The inline filter will keep the water clean and free of debris, protecting the pump and other components.
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Copper Computer Radiators: Two copper computer radiators will effectively dissipate the heat generated during the welding process.
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High Output, Low Noise Computer Cooling Fans: Four high-performance computer fans will be mounted on the radiators to maintain optimal temperature.
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Stainless Steel Buffet/Food Tray: This will serve as the tank or reservoir for the cooling system.
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Old Soda Dispenser Machine Motor: This motor can be repurposed to power the Procon pump.
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Heater Core from a Truck: The heater core can be used as an additional heat exchanger to further cool the water.
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Small Computer Fan: A small computer fan can be used to circulate air over the heater core.
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Scrap Aluminum: Scrap aluminum can be used to fabricate the housing or enclosure for the cooler.
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Angle Iron: Angle iron will be used to construct the sturdy frame for the cooler.
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Fittings, Hoses, Pressure Gauge, and Light Switch: These additional components will allow you to monitor and control the cooling system.
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Torch and Hoses: You’ll need your TIG torch and hoses to complete the setup.
Building the Cooler
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Assemble the Frame: Start by constructing the frame using angle iron. This will provide the necessary stability and support for the entire cooling system.
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Mount the Tank: Securely mount the stainless steel buffet/food tray (tank) within the frame.
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Install the Procon Pump: Install the Procon brass pump, either using a new old stock or salvaging it from an old soda dispenser machine.
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Connect the Pump to the Motor: Connect the Procon pump to the 230-volt, 1/3 hp electric motor with a 1725 rpm speed.
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Attach the Mesh Inline Filter: Install the mesh inline filter to ensure clean water flow throughout the system.
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Install the Copper Radiators: Mount the two copper computer radiators within the frame to effectively dissipate the heat.
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Mount the Cooling Fans: Attach the four high output, low noise computer cooling fans to the radiators to maintain optimal temperature.
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Connect the Quick Connectors: Install the TIG quick connectors, ensuring they are compatible with your TIG torch.
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Adjust the Pressure Relief Bypass: Adjust the pressure relief bypass of the Procon pump to 45-50 psi for optimal performance.
Additional Considerations
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Pressure Gauge and Light Switch: Consider adding a pressure gauge and a light switch to monitor and control the cooling system.
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Water Flow Indicator and Temperature Gauge: Include a water flow indicator and a temperature gauge to track the cooler’s performance.
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Maintenance Access: For easier maintenance, weld aluminum tabs on the inside of the frame to hold a front panel, allowing for quick connects and disconnects.
By following these detailed steps, you can build a robust and efficient TIG water cooler that will significantly improve your welding capabilities, especially when working with aluminum. This DIY project is not only cost-effective but also provides a sense of accomplishment and allows for customization based on your specific needs.