Bringing an Old Miller Thunderbolt AC/DC Welder Back to Life

By Mike attempts | Mar 04, 2020
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Repairing a 38 year old Miller Thunderbolt AC/DC welder. This welder was made in 1982, before they even started using their current logo. It was filled with mice nests, and even some snake skin! The shunt was rusted solid and one of the jack plug receptacles was melted. See the links below for the parts and tools I used:

Jack Plug Receptacle:
https://amzn.to/2JsidDt (affiliate*)

Jack Plugs:
https://amzn.to/2JvjSZc (affiliate*)

Electrode Holder:
https://amzn.to/3bHQ6w2 (affiliate*)

Ground Clamp:
https://amzn.to/2WWEeCp (affiliate*)

#2 Gauge Wire:
https://www.wireandsupply.com/2_awg_Welding_cable_p/wc-2g-01-std.htm

Copper Lug:
https://amzn.to/3dFeEbb (affiliate*)

6-50P 50-Amp Plug:
https://amzn.to/33XGtqy (affiliate*)

Dremel:
https://amzn.to/2UOuRSK (affiliate*)

Dremel Flex Shaft Attachment:
https://amzn.to/2V3A3SX (affiliate*)

Mini Heat Gun:
https://amzn.to/2UvCYV3 (affiliate*)

Dewalt Angle Grinder:
https://amzn.to/2UOxd3X (affiliate*)

Dewalt Crimped Wire Cup Brush:
https://amzn.to/2WYIcuq (affiliate*)

Milwaukee Stick Light:
https://amzn.to/33WCACm (affiliate*)

Ace Safety Blue Paint:
https://www.acehardware.com/departments/paint-and-supplies/spray-paint/general-purpose/1010081

*Purchasing from these Amazon affiliate links earns my channel a small commission. Think of it as a tip that doesn't cost you anything. Thanks for the support!