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figure 6. (Grooved back of the centre
spacer only. )
Before we can bend the ends of the unit
electrodes, we must remove the flux off the welding rods; therefore
exposing the stainless steel wire underneath.Using a hammer an a hard
surface, hit the outer flux off the welding rod wire. Do not hit the
welding rod to hard else you will bend the rod and form it out of shape.
Once you have removed all the flux off the wire gently rub the wire to a
shinny finish with some 200 grade sand paper. Now the ends of both wire
electrode rods are ready to be roll into shape. The outer most electrode
has a half bend the diameter of the 6mm main fixing bolt. By using two
pairs of wire pliers you can form the electrode around any 6mm diameter
bolt. Do not use the main fixing bolt for this process as you may damage
the thread of this bolt. The end of the centre electrode progresses 90
degrees more an is looped into a full circle. The end of the centre
electrode is formed around a larger 19mm diameter bolt or rod. The inner
diameter must be slightly bigger or equal in size to the inner groove on
the back of the centre spacer. A little time and perseverance will see
you succeed in forming this centre electrode circular loop. See figure 7
for electrode end loops.
figure 7.
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Once all the materials are machined and
cleaned of manufacturing errors and general grime, you are ready to
assemble the unit. Assembly of the unit is straight forward. You should
have 5 plates in total, 3 with 12.5 dia holes and 2 with 6mm dia holes
in the centre.These 2 plates @ 6mm holes are the two outer most end
plates. Thread one of the 4 stainless steel nuts onto the end of the
75mm main fixing bolt which should now be cut to length. Thread one of
the outer plates with the 6mm holes right down onto the s/s nut. Thread
the first one of the 3 spacers with collars on next. Next thread a
12.5mm plate on. Be shore that the plate goes over an onto the small
lathed collar, and fits snuggling into position. The centre electrode
will have to be placed onto the main fixing bolt at the same time as the
centre plate and the centre spacer are put into position. Repeat the
process of plates and spacers until you arrive at the end spacer and the
last outer plate. Remember the last spacer does not require a lathed
collar, as the last outer plate has a 6mm hole which by default fixes
the last plate into the correct position You will have to hold the
entire assembly firmly with your hands until you can get the final nut
into position. Before tightening the last s/s nut you must place the
outer electrode under the outer nut as you tighten the whole unit. Its
not very difficult, and with a little practice as you go it becomes very
simple. Refer to figure 8 and figure 9 for any final assembly points and
details. Your final unit should look something like figure 10, but most
likely with square plates instead of round.
figure 8
figure 9
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Alternative
