New consulting relationship with GreenTecAuto begins
What actually goes wrong with the batteries????
A look at todays Hybrid and EV battery packs
Battery packs exposed
Keeping Warm In New England
Plugging into the SUN
Making a small solar concentrator
Building MIMA and the plug in adapters
Converting a telephone truck to electric
DIY dual pulse Capacitor Discharge Spotwelder
Cell Miller mounting the components
Welding beautifully
More snubbing
Beefing up the switching board
Rebuilding the welder
Need better welds
Welder first test
Making some cells for weld testing
More parts of the process
New weld head
Spotwelding fixture #1
More energy
First weld testing
Making a spot welder??
Chevy Bolt EV joins the family
Getting in shape while making electricity
Replacing gasoline with solar electric lawn equipment
What is Genesis One?
How to stop the aging process DIY
MIMA Install Day 2005 a Big Success!
Building a hybrid car grid charger
Tapping into the Wind
Expanding MIMA with the Distribution board ( users projects )

Making some cells for weld testing

Making some cells for weld testing
freeing up the cells

Dan came over and we tried out the weld milling fixture.It worked well, but even at 120psi in the cylinders, the smooth steel battery against the garolite was slipping a bit when we were milling, so Dan put a strip of emery cloth in the jaws and the problem was solved.
The weld spots needed to be smoothed out on the belt sander to remove any residual weld.
The vice air switch was replaced by an air push button valve which was mounted on a bracket and nut that screws right into the quill feed lever, so you line up the weld, press the button with your thumb to lock the vice, pull down to mill the weld, retract the end mill and release the button rotate and repeat, It works pretty slick. The only improvement I can see is to automate the end mill coming down, so one would tap the button, and the vice would clamp,end mill come down to mill off the weld, end mill retracts and the vice would unlock.
rotate the stick, hit it again.