Using Electric Golf Cart as a DC Welder


New Member
Using Electric Golf Cart as a DC Welder:
I have had the need for a portable arc welder on the campus where I work. We have a Lincoln "buzz box" unit, but this requires a special electrical hook up and is not portable. We also have a 120 volt unit, but it lacks power. Then we have a Miller trailer mounted unit that requires a lot of storage space, needs engine maintenance, is noisy to operate, and is not portable.
I have read that off road enthusiasts use paralleled auto batteries with jumper cables as a rudimentary welder. At this point, I considered using a 36 volt golf car as the power source by connecting to the charger DC input. Since most of our vehicles already use the "50 amp North American style connector," I have since converted all 36 volt campus vehicles and chargers to this type connector.

Mcmaster-Carr Parts List:

7043K21 (connector, many EZ-GO already use this part. Specify #6AWG contacts.)

7940A21 (#6 black welding cable. consider #4 if more than 25 feet is needed)

7940A61 (#6 red welding cable. consider #4 if more than 25 feet is needed)

7991A4 (ground clamp, spring type)

7939A9 (electrode holder)

Many of you already have bulk length battery cable. However, the welding cable is more flexible, which makes it much easier for both welding and to coil it up when you're finished. Make sure the wires from the charging connector to the battery pack are at least #6AWG. All of our EZ-GO units are #6. I can weld for quite a long time without needing to charge the battery. Simply reverse any connection if reverse polarity is needed. If less power is needed, just move one of the charger cables to select fewer batteries which gives 30 volt and 24 volt as useful lower outputs. Be sure and remember to move the cable back before recharging!
This setup has been used on a variety of jobs from sealing man hole covers to repairing a cracked truck frame. It is silent, so I can work without disturbing classes or events. There is no need to find a 220 volt outlet or bring the work to the welder. Short cables suffice because I can maneuver the golf car close to the work. I have even welded indoors, something I can't do with a gas welder. Also, one can drive onto an athletic field and repair a cracked goal post on a vehicle/welder that will not damage the turf. Since we have multiple sites, I can just throw this setup, rods, gloves, and helmet in the truck and drive to the other campus, get a golf cart, and go welding. It is silent, lightweight, inexpensive to make, takes up almost no space, and requires no maintenance. Email [email protected] for an image of this setup.



Tennessee Squire