Sunko 788H battery spot welder mods

thingiverse

The Sunko Battery Tagger, fresh from the box, was a dismal affair, with construction quality that defied comparison to any poorly built gadget I'd encountered in years. Opening it up revealed woefully inadequate workmanship, along with wiring that bordered on reckless endangerment. In rectifying these glaring defects, I made some tweaks to optimize its function, which I'd like to share with fellow enthusiasts who value a good tinker. I'll skip detailing the multitude of faults for now and instead focus on the modifications I've implemented – details anyone following this guide can adapt for their own projects. To prevent accidents while delving inside, safety protocol demands that I caution you: exercise care when investigating its innards. 1. Positioning the input socket at the back simplifies storing it away after use with the template provided. 2. Adjustable micro-switch placement streamlines machine setup and usage; adjust as needed for ideal weld timing. 3. Reorienting the main TRIAC allows better airflow, thus improving heat dissipation and longevity. 4. An additional bracket secures electrode holders firmly in place, minimizing the risk of electrode overlap during close operations. By making these tweaks, my modified Sunko battery tager has become easier to use and much safer overall. The parts used – crafted on a compact CNC router from ABS and acrylic – can be replicated for any purpose; DXF files provided.