TIG Torch Reduction

[Ji Gantor]

The most common TIG torch that comes with a TIG welding unit is a WP26.
A WP26 is a 200 amp air cooled torch.
Replacement price runs from $15.00 for Chinese made to $100.00 for USA made.
The WP26 is a great torch for beginners because they are pretty hardy.
But when you start welding more complex shapes the WP26 is way to big to get into a small space.
You can purchase smaller torches but these are usually water cooled or have smaller attachments at the welder. This refit can become very expensive.
Smaller torches except water cooled units are restricted to less amp carrying capacity.

I have found a way to reduce the size of my WP26 so it can go places it couldn't before.
I am not suggesting that others try this, it is just what I have found.

Ji

[Ji Gantor]

The smallest torch that is similar to a WP26 is a WP9.
I purchased the collet holder, collet, nozzel and mid size back cap for a WP9.
You can see the difference in overal length of the two units parts.

Ji

[Ji Gantor]

When the WP26 torch is assembled with the WP9 parts it can be seen how much smaller the torch has now become.
The WP9 torch is only rated to 125amps so there is a reduction in welding capacity.
To make sure I don't exceed the new parts I set the peak current on the welder to 125amps and only run a 1.6mm diameter tungsten electrode.

Ji

[Ji Gantor]

To reduce the overal length futher I use a button end cap.
There is another down side to reducing the length of the torch and that is the length the electrode can be.
Most electrodes come in 175mm lengths so you have to cut them down to size, but this is a small price to pay to be able to get right in there and get the job done right.

Ji

[TT5 Matt]

that's a usfull 120mm reduction what sort of $ did the bits cost and can you get them at your local cig shop?

[Ji Gantor]

All the parts cost $20.00
I purchased them from my local welding supplier so may be.
Good luck

Ji

[Slakewell]

You can also buy flexable heads for getting into tight spots. I had one for welding steam pipe in powerstation's, There only good for 120 amps thou.

[Ji Gantor]

Hi Slakewell,
Yes I have a Profax flex head, they are great.
They tell me if you keep bending it the head breaks off.
I have been using mine since Christmas without any problems so far.

Ji

[Slakewell]

I had a couple of them, broke one just because I got it too hot trying to repair something I shouldnt have. I used the other one just for pipe preseaure welding and had no problems and I used to move the head all the time in confined space. I think the ones I bought were only rated to 140 amp's.
I only have a little 150 amp ac/dc unit now. I sold my Miller 400 as I dont have the power source to run it now.

[Ji Gantor]

Yep 3 phase is pretty expensive, even the plugs cost a few hundred bucks.
Do you have any images of your TIG welding?

Ji

[Slakewell]

I finished this a few weeks back its a special vehicle set up for drilling soil samples took me 9 weeks but I did everything including the hydraulics.
The 100 litre oil tank in the head board is all tig welded as are a few other bits.

[Ji Gantor]

Hi Slakewell,
That is awsome.
How many tests did it take before the oil tank had no leaks?
9 Weeks you must have been happy to see the back of that truck.

Ji

[Ji Gantor]

I used the new WP26 hybrid WP9 torch yesterday.
Total welding time 30 minutes on a bike frame.
There is no way I could have got the torch into the position required if it had been a standard WP26 torch.
I pressed the foot pedal to the floor when fixing the 4mm plate to the frame without the torch heating up (machine set at 125amps).

Ji

[Slakewell]

Hi Slakewell,
That is awsome.
How many tests did it take before the oil tank had no leaks?
9 Weeks you must have been happy to see the back of that truck.

Ji

There were so many small details on that truck. The tank had one small leak were I pluged welded one of the baffels when I tested it with air and soapy water. One leak in a tank that took 3 days to make isn't to bad and If I had enough juice when welding It woudnt have happend only 150 amps and 6mm Alum is hard going.

[Ji Gantor]

Hi Slakewell,
It only took 1 test, bravo.
6mm aluminium plate with only 150 amps, no wonder.
I use 90amps for 3mm aluminium.
That truck is truly a monument to your talent.
Well done

Ji