1st Aluminum Welding project: Inter-cooler V-band Setup

[outlawstar1023]

I recently Bought an Everlast 200DX 220V tig/stick welder. I don't know much about welders, but after reading a lot of about this brand on weldingtipsandtricks.com I decided to go with it. It comes with a 5 year warranty ( I know it sucks to have to ship it to get it fixed) but for the price it seems a really good choice for home based hobbyist who don't want to spend close to 2k on a good welding machine with the same features this one offers. So far this welder is amazing in my opinion, no regrets.
If you are interested ill speak more about the welder, but for now I basically wanted to post some pics of my 1st Aluminum project.

1st welding project: Aluminum V-band inter-cooler setup.

This is the first time I have welded and I think i seem to be doing okay, not sure if the welds are amazing, but I do hope to improve over time. I'll post more pics as i finish the setup and see what you guys have to say, thanks.

p.s. I am in the NY, queens area. If any guys out here want to get some work done, ill hook up with good price :)

This is the Whole Everlast 200DX 220V welder kit.
http://i42.tinypic.com/121ppbk.jpg

1st set of practice beads that I ran on some spare pipe.
http://i44.tinypic.com/keg0on.jpg

2nd Set.
http://i43.tinypic.com/rt3tzp.jpg

1st 2.5' ID V-band flange welded.
http://i39.tinypic.com/21erupj.jpg

2nd one.
http://i44.tinypic.com/zmlhy1.jpg

2nd on with a different angle.
http://i41.tinypic.com/ogcq9u.jpg

2.75" ID V-band welded onto the inter-cooler.
http://i42.tinypic.com/2z9hait.jpg

[racers4life77]

As long as it holds, it's good. Where did you get the welder from?

[outlawstar1023]

They are located in California, I placed my order over the phone and had the welder in 3 days. They also gave me a 60 day money back guarantee if I were unsatisfied for some reason.
Everlastgenerators.com is their main website, they seem to have a good forum up there if you want to look into it.

[teh smithers]

Did you have any prior experience at all, or just picked it up and started welding? I'd like to fab up my own intercooler kit as well, but I don't know the first thing about welding.

[ch1873857]

http://zilvia.net/f/tech-talk/171389-fabrication-thread.html

[outlawstar1023]

I had tried Mig welding once with the spool gun but that about it.
I just got frustrated with need to weld to so many times and having to pay crazy amounts for a single aluminum weld.
So I decided to just buy one and teach myself. After a lot of you tube videos and reading, it wasn't as hard as it seems. Just have to figure out a few basics.

[Sennate]

your welds look pretty good from what I see. Keep it up!

[Darren]

Nice work for being your first time welding aluminum, this is not the easiest material to weld!

Also:::

http://zilvia.net/f/tech-talk/171389-fabrication-thread.html

This is where you put this sort of stuff.... Lots of good info too for the aspiring welder / fabricator

[outlawstar1023]

Thanks you!
how do I move it into that thread?

[blueshark123]

This thread is gonna get locked so post in the fab thread. If im ever around ill make sure to pass by i have a gas scooter when i was younger that the aluminumn cracked i need weleded lol.

[blueshark123]

Thanks you!
how do I move it into that thread?

You cant move it copy and paste only lol

[Fred Allen Burge]

Looks good for your first time, nice job! I had a Syncrowave 180SD a couple years ago but sold it, regret that! I think I may get one of these Everlasts soon. Does it "feel" kinda cheap, like a Godspeed part or other Chinese made thing?

[Broadfield]

Those do look good for a rookie. How much did you end up spending on the setup?

[tuktuk23]

dammit i need to learn aluminum welding...this may have given me the motivation i need!!

nice welds though man. props to your first time!

[blo0d]

Those do look good for a rookie. How much did you end up spending on the setup?

+1 on that info... also, how much was the shipping weight if you dont mind? :wan:

[outlawstar1023]

Alright so here is the breakdown. I am going to try and answer all the questions before this thread is closed/locked.

1. the machine was 975$$ shipped to my house and it weights around 56 pounds, very light and portable. The features it has you would have to get the syncrowave 200, which is 200 lbs. i think you would have to spend 3k to spend on and square wave based technology welder with pulse features that is this light... I could be wrong, cause there are thermal arc welders that people seem to love a lot.

2. Things you would need:
-- Welder kit. 975 shipped
-- Consumables ( tungsten, aluminum/ss/iron/titanium metal filler rods, Argon gas cylinder, gloves..) The gas cylinder i got on ebay: 80 cubic feet for 180 shipped. Consumable prices vary but 10 lbs of aluminum rod was 60 on amazon.com
--- wekding mask 80 - 400 $$
In the end i think i have spend around 1350-1400 dollar for everything to get started on the welding.
Actually I had to get a 220V source put in the house which was a 100 $ cause my Neighbor did it.

I think if you read a lot and figure out the science behind welding, with a combination of trial and error, its not as difficult as it may seem, now to make it look like dime stacks and pretty might be a different story.
I went through 1 whole 80 cf of argon before i got a hang of it, with about 5 hours of practice.

[bataangpinoy]

i have work for you. contact me at [email protected]

[outlawstar1023]

Also the welder does not at feel like cheap plastic or Godspeed products.
I guess you could say it's like Stance when they tried to compete againt twin or cusco, off course its a different price range of products but they both deliver. Over all it's a solid feel with good knobs and a digital read out. The pedal is probably the cheapest feeling thing but it gets the job done.

[atutt]

Also the welder does not at feel like cheap plastic or Godspeed products.
I guess you could say it's like Stance when they tried to compete againt twin or cusco, off course its a different price range of products but they both deliver. Over all it's a solid feel with good knobs and a digital read out. The pedal is probably the cheapest feeling thing but it gets the job done.

I can tell you haven't used many machines.

They are definitely made from cheap plastic and they definitely feel like it.
I've used a ton of different machines and from a ton of different companies.

It's more like Mastercraft compared to Snap-On. You can feel the difference between the two, but treated properly both tools perform just as well.

I have a 250ex. I've had it for just under a year now. Aside from the noise of the fan and the cheap feeling accessories, they are GREAT machines if treated properly.

I HIGHLY recommend these machines to people who don't weld for 9 hours everyday for 6 out of 7 days every week.

[outlawstar1023]

This is actually the only one I have used, just seen other ones in person and no hands on. Actually, till today I still have less than 10 hrs of actual welding time since I purchased it beginning of Jan 2012. The acc might have cheap feel but the actual unit body itself does feel pretty good and is made out of metal.
I would have went with the 250ex but I didn't want to spend even more tryin to get a water cooler or the gun 250ex comes with. Just out of my budget. I'm hoping mine last long as well. I am happy with it and love it so far.

[atutt]

This is actually the only one I have used, just seen other ones in person and no hands on. Actually, till today I still have less than 10 hrs of actual welding time since I purchased it beginning of Jan 2012. The acc might have cheap feel but the actual unit body itself does feel pretty good and is made out of metal.
I would have went with the 250ex but I didn't want to spend even more tryin to get a water cooler or the gun 250ex comes with. Just out of my budget. I'm hoping mine last long as well. I am happy with it and love it so far.

From your picture, I can tell you that the torch on your machine and the torch on my machine are the same.

There are people who have adapted more traditional and higher end torches to their Everlasts for around $300. Most people have also adapted other pedals or had custom pedals made for theirs to.

I personally used to HATE torch mounted trigger torch set ups...

.... But I've grown very fond of my Everlast torch. I haven't used my pedal since May or so.

[ch1873857]

which v bands are you using if you dont mind me asking.

[outlawstar1023]

which v bands are you using if you dont mind me asking.


I get these from Siliconeintakes.com made out of 6061-T6 aluminum.
I Have had real good experience with them, buy all my pipes from them as well, and these v-band seem to hold up great on some HP cars my friends have. Maybe a little oil on the rubber to keep it from becoming stiff and they are awesome. I don't know how they compare to Vibrant or other brands, i know the other ones have a lip on it rather than an o-ring that goes in between. Just like this design better i guess. OBX has really good sets as well that are 30$ for clamp and v-band as a kit.
I personally think vibrant rapes you for every little piece and its just out of my budget.
http://i41.tinypic.com/2hqb3v5.jpg

[slider2828]

I use silicon intakes for all my silicon stuff... Great quality and good price! Awesome welding though!

[KoukiMonsta]

From your picture, I can tell you that the torch on your machine and the torch on my machine are the same.

There are people who have adapted more traditional and higher end torches to their Everlasts for around $300. Most people have also adapted other pedals or had custom pedals made for theirs to.

I personally used to HATE torch mounted trigger torch set ups...

.... But I've grown very fond of my Everlast torch. I haven't used my pedal since May or so.


Glad to see your input here atutt. I have definitely seen pics of some BADASS work you have done.

I actually was recently looking at the everlast machines, well i have been looking at all sorts of tig stuff. the 110 mig is just getting...old. I need to build some aluminum skills.

anyways from what i was reading seemed like a good 'at home' rig for the garage guy like me. so this is helping me further validate that. what would you say is the biggest issue with them? cheap plastics, accessories etc?

[atutt]

Glad to see your input here atutt. I have definitely seen pics of some BADASS work you have done.

I actually was recently looking at the everlast machines, well i have been looking at all sorts of tig stuff. the 110 mig is just getting...old. I need to build some aluminum skills.

anyways from what i was reading seemed like a good 'at home' rig for the garage guy like me. so this is helping me further validate that. what would you say is the biggest issue with them? cheap plastics, accessories etc?

Thanks! but there are far better fabricators and welders than me on here, lol

My BIGGEST issue is the fan. It's on ALL THE TIME. It's not a bad thing, it's just unnecessary. And it's kinda loud.

For some people the accessories may not live up to their standards and do not like them. Me, I just adapted to using them and rather enjoy the torch mounted trigger set up now.

One day I will switch the torch and pedal out for a high end torch and pedal set up, but that's low on the list of things to do.

The plastic is cheap, but the overall construction is still pretty solid. I'll admit to banging mine around a little more than I should.

These machines are great for the at-home-fabricator. Probably not ideal for 9-hours-a-day-6-days-a-week industrial type work. (Although I do trust my machine to do more than the at-home-fabricator)

I have recommended these machine to two of my friends and they couldn't be happier with their machines.

I feel that the majority of the people expect far too much out of them.
You get more than what you pay for, but you have to remember they are still "made in China" machines.

-Adam


*ninja edit
I recommend switching out the regulator for a more industrial unit. I've always had about 6 reg's on hand so it never phased me.
Plus the Everlast regulators are measured in different flow rates than what I'm used to, and I only use ball/float type reg's unless I'm purging.

[KoukiMonsta]

I was just in the fab thread the other day and recalled seeing something I liked that you posted. Don't recall now.

Thanks for the info sir. It will still be some time before I actually purchase a machine. Im just an at home garage kinda guy. Only fab work i do is for myself and nothing impressive. But always trying to gain knowledge on it all. Appreciate the input man!

[ixfxi]

this looks similar to the chinese-made longevity-brand welders

i cant comment on the durability of these units. from most people ive spoken to, the heavier machines are designed to last a lifetime. though, all of the smaller inverter welders tend to have a much shorter lifespan in exchange for convenience and portability.

i bought a lincoln and prefer buying from a company that has been in business for ages, but to each his own.