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To: <>
From: (Tyler Stewart)
Date: Wed, 02 Jul 1997 23:48:59 +0100
>      Exothermic welding is the best method for interconnecting
>      dissimilar metals. Basically it heats everything up to a very
>      high temperature very quickly and so "fuses" the metals together.
>      Basically this is done with formfitting molds into which shot
>      metal (something akin to gunpowder) is poured and then ignited.
>      The resultant bang! is a great cathartic for stressed-out folks
>      who eschew handguns. :-)
>      Erico in Cleveland, Ohio, sells these systems under their
>      trademark CADWELD. It's probably too expensive for a one-shot
>      application. For a club, however, it might be something to
>      consider. Of course, you can also have a professional come in and
>      perform the work.
>      Depending on the situation, you can perform an exothermic weld
>      and still have the capability of disassembling the system. As a
>      general rule, however, once it's exothermically welded it's a
>      done deal until you take a sledgehammer to it.
> --
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Actually, Enrico/CADWELD sells a product line called a "One-Shot" that
is fairly affordable, especially by Polyphaser standards.

These One-Shots sell for about $6 a piece or so.  They are just that:  a
single use mold for use with typical
ground rods and popular sizes of ground wire.  Each One-Shot has
everything you need for the single weld:
a ceramic form with gaskets and fittings and a small vial containing the
powder and metal flakes.  The only
other thing you need is a spark source, which you can buy from them for
a couple of bucks, or use one from
a propane torch, etc.  They are very simple and quick to use.  AFter the
metal flows into the mold, solidifies, and cools, you just hit the mold
lightly with a hammer and it breaks up, leaving the completed weld
joint.  It beats the heck out of clamps and conductive grease for
longevity and physical strength.

If you are going to do a lot of the same type of weld, you might want to
consider buying a reusable mold from
them.  They are a lot more money up front, but you might save  on a big
job or for a club purchase.  

73, Tyler K3MM

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