kWeld DIY Spot Welder - Custom Battery & Enclosure

Hi folks. In this video I show and explain how I built a custom battery & enclosure for my new kWeld DIY spot welder that I purchased from Keenlab. If you're interested, you can download the .stl files for 3d printing the custom enclosure and find the kWeld spot welder and 38120 battery cells at the links below.

Get the files for the custom enclosure here:

Authorized kWeld distributors

Individual 38120 cells:

38120 cells in modules w/ bus bars, screws, holders, etc:

[MiniLuv-]

That was so well worked out - the case, the assembly, the cabling and the performance troubleshooting.

[anthonycadogan]

This is awesome, I came here because was looking for a way not to use kcap. Yes headway 38120 are perfect for the job.

[markb]

Takeaway: Respect the k-weld. Acquire the k-weld.
I think this is the best build i’ve seen on a portable battery-powered, full-function spot welder.
I’ve been using a beefed-up inexpensive spot-weld pcb on a 4s2p headway pack for a few months & it works great, but I’d like to do a similar build to this ultimately. Sweet build!

[josephrobertson]

Very nice and very professional build. Thank you for clearly explaining all phases of this build James.

[bigwave_dave]

Nice build! K-Weld is great. On mine, I just used a large RC Car battery which proved more than adequate for spot welding ni-chrome tape onto 18650 batteries. I use a multi-mode charger to top up the battery prior to use. Even now, storing Li-Po batteries give me the willies so I store it in a steel toolbox when not in use. An interesting upgrade might be to use super-capacitors instead of Li-Po batteries but lately, I'm not making too many battery packs.

[brodyport]

Just saw the battery build and couldn't get over how trick looking that kweld case was and was thrilled to find a video for it too. And overjoyed to find that you also released the files for it. Will have to check if I have enough headway cells to make one. I don't think I have copper laying around so might have to just spring for the case from battery hookup. Probably be best to retire the old poor lipo.

[turnerhayes]

Awesome work James, as usual. Watch out for puncturing the battery (especially on the negative terminals). That can be a nasty emergency to deal with (I recommend a metal trash bin while making the battery). I'm looking forward to the rest of the bike build. Take care!

[willptech]

Very nice and clean build! I love it and what I can’t believe is the fact you made it free!

[jeffschroeder]

Beautiful implementation, extremely well thought out!

[Starper]

Я не даже добре розумію англійської мови, та ваша робота чудова, якість на вищому рівні! 🤗👍👍👍👍

[muramusan]

Wow what an awesome looking welder for batteries, wish this was a kit itself, love the projects. How much did this cost you in total in materials?

[leighamos]

Beautiful work awesome job now you have a welder

[ghffrsfygdhfjkjiysdz]

Overall, i like your set-up. Couple suggestions:
1. polish the electrode tips with sand paper. You want highest resistance to be between nickel strip and battery, not somewhere else in the circuit.
2. You may want to consider a 4s instead of 3s configuration. Been using 3s set-up for a long time, but sometimes it just does not have enough voltage to drive the amps.
3. With 100J and 1200A i welded through 7, yes 7 strips of 0.15mm nickel, but i did have one electrode on the longer bottom strip and another on a shorter top strip. Point being is, you can do allot more than is reasonable with this welder if you prep for it just right. Having a blunt tip electrode as a ground on the bottom piece is a good way to force all current through weld spot without marking up bottom piece; but this is a unique case.

[viking]

I would love to see you try to spot weld pure copper instead of pure nickel, I saw some people be successful with a K-weld but your design would be perfect if it does that too!

[Codyhumburg]

If you punch or cut a slot or hole in the pure nickel strip, you disrupt the path of least electrical resistance for the spot weld. This forces more electricity down and across the cell. More energy is used for the weld than arc across the nickel. Requires less energy

[sammarch]

This is a nice enclosure and nice battery tab welder good job I also buy a lot of batteries from Battery Hookup

[itsgulshanB]

This what i'm asking about in your last video. Nice video BTW

[ryanmerrill]

I do see a problem with your design. I build a ton of batteries and the kweld is an amazingunit. I've been abusing mine for over 3 years. If you're doing a ton of back-to-back Welds you know how hot the electrodes get. The kweld unit itself gets very hot. Most of us incorporate a fan into the design of the case.

[newageautotechnology]

Excellent job. Do you sell them in a kit ? Or where can I get the stuff to build one? I'm going to build a solar backup generator for camping.

[MagnumPopeye]

Would like to see someone test/use the batteryhook up spot welder they have/had.. If they ever come back in stock.. Looked very interesting when I saw it.