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obsolute parts for a Miller Thunderbolt 225,,, |
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desertjoe
Orange Level Access Joined: 23 Sep 2013 Location: New mexico Points: 13528 |
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Posted: 24 Jan 2024 at 8:52pm |
I picked up a great looking Miller Thunderbolt 225 AMP Style JB-41 Arc welder for a really good price at a yard sale, The STYLE JB-41 is the only'ist numbers on the box. The PO said he stopped using the welder due to the blades on the tiny cooling fan broke off. He removed the power cord and installed on new machine he bought. I installed a short power cord I had and it does weld but I only run it for about 2-3 mins. because of missing fan blades. I have looked on internet for obsolute Miller parts and Amazon and Ebay with NO luck,,,!! Any one got an Idee,,,??
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Codger
Orange Level Joined: 23 Dec 2020 Location: Illinois Points: 2022 |
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Replace the fan with a "Muffin" fan which is an axial fan commonly available. What is is about 8" diameter? Doesn't have to be a welder fan, just something to move air across the transformer. While apart clean that transformer with solvent and compressed air.
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A career built on repairing and improving engineering design deficiencies, shortcomings, and failures over 50 years now.
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desertjoe
Orange Level Access Joined: 23 Sep 2013 Location: New mexico Points: 13528 |
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Some pics,,,,, |
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desertjoe
Orange Level Access Joined: 23 Sep 2013 Location: New mexico Points: 13528 |
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Hey Codger,,when I was doing some study'in on my Lincoln Mig, I did read where some of those cooling fans were 115V and some were 220V,? I think this one has about a 3" daimeter fan,, UMM what is a muffin fan,,,,,,????
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steve(ill)
Orange Level Access Joined: 11 Sep 2009 Location: illinois Points: 80372 |
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JOE !!! I gots that same welder with the same problem !!.. Yes, the fan was 240 v.. I looked on AMAZON for a "exact fit" .... MUCHO $$$ ..... I finally took a 120v muffin fan i had ( thats a small box fan) that was about 6 inches in diameter and STUFFED it into that space.. ITS TIGHT !!... But i gots LOTTS OF COOLING !!..
You might want to set a 20 inch box fan next to the welder and "TEST WELD" to make sure the COOLING solves your problem and you dont have ADDITIONAL WEAK parts ?? Edited by steve(ill) - 25 Jan 2024 at 8:43am |
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Like them all, but love the "B"s.
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steve(ill)
Orange Level Access Joined: 11 Sep 2009 Location: illinois Points: 80372 |
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I used something like this ... I put a couple pieces of all thread and PVC pipe spacers to hold it up 2-3 inches off the bottom of the welder.. I put the fan WIRES on one leg of the 240v to get 120v supply.. This one is kind of quiet (47 db) and it puts out 110 CFM which is good... Make sure you get a high volume fan, not 40- 50 CFM..... 120 mm is about 4-1/2 inch diameter..... this one is on AMAZON.
Edited by steve(ill) - 24 Jan 2024 at 9:44pm |
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Like them all, but love the "B"s.
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steve(ill)
Orange Level Access Joined: 11 Sep 2009 Location: illinois Points: 80372 |
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This is the SPEC on the above fan... more like 4.7 inches square
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Like them all, but love the "B"s.
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Coke-in-MN
Orange Level Access Joined: 12 Sep 2009 Location: Afton MN Points: 41485 |
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You can use a 110 V fan and hook to one leg of 220 V but be sure your using a neutral on the circuit . Otherwise your case will be hot or fan will not run .
You could mount the FAN EXTERNALLY also - I have a couple old battery chargers with 100 A + output and use small fans to cool the transformers on those , even after I replaced the selenium rectifiers with diodes and heat sink copper plates . |
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Faith isn't a jump in the dark. It is a walk in the light. Faith is not guessing; it is knowing something.
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steve(ill)
Orange Level Access Joined: 11 Sep 2009 Location: illinois Points: 80372 |
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This one is closer to 6 inches square and 2 inches think.. MORE AIR.. and 240v power..... just measure and make sure you can GET IT INTO THE BOX !!
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Like them all, but love the "B"s.
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steve(ill)
Orange Level Access Joined: 11 Sep 2009 Location: illinois Points: 80372 |
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The ORIGINAL fan is very similar to a BATHROOM VENT FAN ....I was looking at these "replacement type" fans, but noted that they have about the half the air flow of the 4.5 inch Muffin fan above..
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Like them all, but love the "B"s.
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desertjoe
Orange Level Access Joined: 23 Sep 2013 Location: New mexico Points: 13528 |
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Hey Steve that small bathroom fan sure looks like whats in the Miller,,,but,,I'm gonna go with your Muffin fan suggestion in 240 volt and get that dude to welding,,,,!!! Thanks to all of ya'll for all your help,,,
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steve(ill)
Orange Level Access Joined: 11 Sep 2009 Location: illinois Points: 80372 |
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Put a box fan next to the welded and TEST it today.. Make sure you dont have other WEAK electrical parts !! YEA... muffin fan has TWICE the air flow.
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Like them all, but love the "B"s.
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Thad in AR.
Orange Level Access Joined: 12 Sep 2009 Location: Arkansas Points: 9424 |
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Is that a DC welder?
We need details |
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steve(ill)
Orange Level Access Joined: 11 Sep 2009 Location: illinois Points: 80372 |
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I think the WHITE FACE units were from the 1970- 80 era.. I "think" they were all AC units.. Mine is 1990 and has a BLACK face on it and is AC/ DC combined... Little more CROWDED on the inside of the box.
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Like them all, but love the "B"s.
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desertjoe
Orange Level Access Joined: 23 Sep 2013 Location: New mexico Points: 13528 |
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OK,, I decided the idea of doing a "Trial Run" to se if there is any good reason to keep on working on this machine. There is NO tag on the machine but writing states it is an A/C machine. The only numbers anywhere are "Style JB-41" stenciled at center top of face. I had to machine some quick attach pins to adapt my Lincoln lead ends to the Miller ports and I notice the LOW port has been removed entirely. I then see where the PO had taped up the big copper wires that were on the outlet port from the Transformer,,,Hmm? Bad JUJU,,?? My thoughts here are that the red plastic quick attach port for the LOW had broken and PO just removed it and taped up the big copper wires inside box from Transformer,,? Got everything ready and turned that mother ON,,,,,! The fan motor has bearings gone and sounds terrible, so I disconect the power cable and disconnect the cooling fan,then try it again. The heat setting crank aT TOP of maching is quite stiff and will need some cleaning of the brownish varnish looking "stuff" on the sides of transformer and if possible will have to be taken apart to clean that varnish stuff before the sliding UP and Down part to adjust heat settings easier. I then notice that ,,,,,,EITHER the "Black Plastic SLIDING part in center of transformer and controlled by the Crank is a TWO piece or it has broken right in the center in the straightest crack you ever seen,,!?? I set the heat at 90 and this will weld quite nicely with 6013 in 1/8" but DOES stick a few times,,,,maybe get some 6011,,?? IF the big black plastic adjuster on the transformer is not broken,,,, then maybe there is a decent welder hidden in this project,,,?? Steve has given me a link to a 240V cooling fan that will take just a pair of minutes to install,,,,at $26 plus a replacement port for the LOW CAN'T BE TOO EXPENSIVE,?? What ya'll think,,,,??
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steve(ill)
Orange Level Access Joined: 11 Sep 2009 Location: illinois Points: 80372 |
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I run 75 - 95 amps on the HIGH side and have not moved the cable to the LOW for 30 years.... Just a thought .
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Like them all, but love the "B"s.
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desertjoe
Orange Level Access Joined: 23 Sep 2013 Location: New mexico Points: 13528 |
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Hey Steve,,,you know for $23, and a pair of minutes, I could have a decent back-up arc welder,,,and a Miller at that,,!! I agree that you should not have to be changing heat very often altho, I would like to try and remove the black plastic chingas that slides up and down to adjust the heat as there is a fair amount of brownish looking "varnish" that i'm sure would prolly help all things welding if cleaned up,,,?? OF Course next thing would be to put a set of wheels( which I happen to have over there pointing to corner) this sob is HEAVY,,,!!!
Edited by desertjoe - 28 Jan 2024 at 8:14am |
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steve(ill)
Orange Level Access Joined: 11 Sep 2009 Location: illinois Points: 80372 |
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YEP... mine got wheels the day after i got it 30 years ago !! Home made.. but looks a LOT like that 2 wheel cart for the wire feed welder !!
I would also "FIX" the welder with the LOW range, and worn plastic parts.. Got to keep things in top shape with routine Maintenance !
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Like them all, but love the "B"s.
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jaybmiller
Orange Level Access Joined: 12 Sep 2009 Location: Greensville,Ont Points: 22291 |
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DJ, get a 5# box of 7018AC rods. be sure it says AC at the end. It's specifically made for Allis Chamlers tractors, er.....AC welders. Have used it for decades as I just have a Lincoln AC-225-S. Arcs nice, smooth, consistent welds. My backup is 6011, aka 'farmers sticks'. smells like smouldering pants on fire, not near as nice. The BIG thing with rods is to keep them warm and dry.Store in house on top of furnace is good. ANY moisture and you'll get 'problems'...hard to start, misfires,zip not ZAP.... If you don't get a 240v fan, use 2 , 120 fans in series. LOTS of airflow.....
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