I was describing general methods, not specific to your application. In yours I would definitely not take a low-effort lazy way out. Technically there would be little problem if the 18AWG wire could handle your current, but that would then mean your 8AWG is hugely oversized and a massive waste of space on the core so you're still better off taking it all off and rewining if with 18AWG if that was the case.The other reason I'm reluctant to use the toroid is because the welder is using 8g wire which is much thicker than the gauge on the toroid. Seems counterintuitive to send 8 gauge into 18 gauge and back to 8 gauge again.
In a weld set the choke 'smooths' the arc & produces a cleaner weld.
Often in cheap sets its ommitted altogther.
Really you should obtain an inductance value & design the choke to fit, your torroid will not be up to much, how much inductance do you want?
Commercial sets, at least good ones have 3 or 4 outputs from the choke brought out to seperate ground terminals so you can select how much choke you want.
In yours I would definitely not take a low-effort lazy way out.
If your doing this with the same welder in the Youtube video, I think you will be dissatisfied when your done, just my oppinion as a welder. The reason I say that is even after putting a DC converions on it you still don't have a Mig welder. Those flux core welders are a modified stick welder. They don't have the correct type of transformer design to be a Mig.
A Mig is a generally a CV constant voltage welder, but that flux core welder is a CC constant current machine. That's one thing the guy in the video dosen't address. He is correct that it will cut down the splatter when using the flux core wire, but it won't weld as a Mig any better.
If you only need to weld a few times a year that $50 would have been better spent on paying some one to do the job. Some one that will get a good result for you.
1. Use the toroid? (still worried about connecting 8AWG to the much smaller wires on the toroid)
2. Just wind heavy wire around the stripped down core? How much? Inductance? Neither of those guys seemed to pay particular attention to the size or extent of the windings.
To my simple mind, I don't think you should hook up to the existing wires of the toroid. The video shows him having 2 bare toroid "forms" and winding a new one over them. I've even seen some chokes wound on a plastic core a so called 'air core'.
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