Modernization of the mass clamp of the welding machine

It would seem: “Well, what can be upgraded in the mass clamp (or mass holder)?”

Well this is the simplest device ...! Usual clothespin with wires!!!

So something like that ... But! Each welder will confirm that poor ground contact makes you nervous and slows down the work process. Constantly have to move the clamp to "catch" the contact.

In addition, over time, the mass clamp burns, the spring weakens ...

All these troubles can be avoided by slightly modernizing the clamp. It is advisable to do all these manipulations with a new clamp - there will be more sense :)

So, we will talk about mass clamps of this type:

The biggest disadvantage of this clamp is that, in fact, contact with the product is carried out at one point. The current passes through only one half of the clamp.

The current passes to the second half through the spring and through the axis connecting the two halves of the clamp.

As you understand, heating occurs in these places due to poor contact. Most often this happens when the second half of the clamp has better contact with the part than the first (to which the core is connected). Excessive heating of the spring leads to its release and it loses its elasticity.

The way out of this situation is simple - you need to install a copper jumper between the halves of the clamp.

On sale there are quite a few varieties of clips with jumpers. You can buy a ready-made one, or you can modify your clamp.

The clip shown in the photo below was sold with a jumper. But its length was so small that literally on the very first day I accidentally burned it (when installing on a sheet of metal, I installed the clamp too far from the edge, the jumper touched the edge of the sheet and when the arc was ignited, the jumper burned out like a fuse). I made a new jumper more authentic.

This design undoubtedly provides better contact with the part.

But! And it can be improved!

To do this, you will need a brass plug for a 1/2 inch pipe.

Drill in the center, a hole with a diameter slightly larger than 6mm (I did not manage to do it in the center, but this will not affect the quality of the product).

Lightly grind two opposite edges (with a file, grinder or emery)

And now install in your clamp instead of the factory U-shaped profile.

Under the brass plug, be sure to clamp the copper jumper.

This refinement will allow your clamp to last longer, and contact with the part will be more reliable. Brass does not oxidize, its resistivity is lower than steel.

I installed the brass plug on one side only. If desired, you can install on two halves. But in this case, you will have to reduce the height of each plug by 5mm - otherwise, it will be difficult to mount it on large parts.

I wish you success in your work!