The Sunko battery tagging welder straight from the box is quite the most shabbily made bit of kit I have come across for many years. A look inside revealed the poorest quality workmanship together with some dangerous wiring.

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While correcting these faults I made some mods to help with the welders intended purpose, which I would like to share with like minded souls. The list of faults is too long for this saga so I will concentrate on the mods which for anyone that can understand this script will be able to adapt for their own use. The health and safety police require me to tell you to be careful while poking around inside.

1, Input socket on back of housing makes it easier to put away after use, using the template. 2, Adjustable micro switch position which helps with the machine setup and use. It can be positioned so the weld takes place when you want it to.

3, Reposition the main TRIAC to a location which has access to some air. 4, A brace to hold the front of the electrode holders steady so that the elctrodes can be brought closer together for small batteries without the risk of them touching. I filed some flats on mine to facilitate this. After all of this I now have an easy to operate and a much safer battery tagger. I made the parts on a small CNC router out of ABS and acrylic however the DXF files can be adapted for any use.

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