In this part you will see: Replacement of all internal power cables with 25 mm2 copper conductors and addition of an extra choke for higher inductance. I also made a new 25 mm2 Cu ground cable with a 200A clamp.

After modification the welder welds more smoothly. Because of the extra choke, it fires better when spotting lower currents and sizzles less.

The aluminium cables inside the welder are approximately 1 m long and have five connections with poor quality thin flat crimp connectors. There is a voltage drop across them.

I make all modifications so that they can be returned to their original state.

To replace the internal cables: About 1 - 1,2 m of 25 mm2 welding cable, 2 pieces of crimp cable eye ring terminal 25/6mm and 3 pieces of crimp cable eye ring terminal 25/8mm. If you also want to add a choke, then you can use a 13uH, 180 A choke like FERYSTER DEHF-42/0.012/180.

To make the ground wire: 3m (or as required) of 25 mm2 welding wire, a welding clamp with a good quality copper jaw (200A or 350A), and a 10/25 cable welding terminal.

3D model choke inductance holder is downloadable:
[ Ссылка ]

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