Saw this on Ewe Toob, so it must be true...

Take a microwave transformer and removed the secondary winding. Replace it with a couple of loops of welding cable. The result is low voltage (mine puts out a bit less than 3VAC) and high current. I don't have a way to measure mine, but the one I modeled it after was in the mid-50 amp range.

I plugged it into the foot switch operated outlet on my Milwaukee portaband stand and did a couple of proof of concept welds.



Worked fine on some 26 gauge galvanized sheet. I can see that being very handy.



Worked pretty good on some 16 gauge stainless after I buffed up the contact area. Took a lot longer (10-15 seconds vs. 2 or thereabouts) but certainly doable.

Now that I know it works, I'll refine it.

1. Better electrode jaws to keep the electrodes in alignment.

2. A handle on the moveable jaw to allow me to put some pressure on the joint.

3. Maybe different electrodes. I'm using brass because that's what I had on hand. Might copper be better?

Today, a spot welder, tomorrow a transmogrifier.
An inventive youngster like you should have a sidekick named Hobbes.