How to Make a Water Cooler for TIG Welder

One of the features that mark the TIG welder is the production of a bright white-colored electrical arc. This type of welding is designed to ensure the continuous welding of certain kinds of metals such as aluminum and stainless steel.  When doing the welding, the TIG welder can get very hot, if you aren’t using a water coolant.

Types of TIG torches

There are different kinds and sizes of TIG sizes. No matter your amperage needs and budget, you can find some good options. But generally, TIG torches can be divided into two major categories. These are air-cooled and water-cooled torches.

Air-cooled torches

The air-cooled TIG torches usually contain one gas hose. This means that your weld puddle is protected by Argon or Helium from contaminants. The gas will also cool down the torch. The one drawback of the air-cooled TIG torches is that they can take a longer period to cool and aren’t effective in handling very high temperatures.

The gas cooling process is usually slower and this can make them overheat easily. These TIG torches are suitable for thinner material and small projects around the home. However, there are bigger air-cooled torches that can handle the higher amperage when correctly used.

Water-cooled torches

The water-cooled TIG torches contain 3 inputs with 3 respective hoses. There is a shielding gas, water input hose, and a water outflow line. One of the advantages of these TIG torches is that they don’t overheat as fast as the air-cooled torches. This makes them the right choice for professional fabricators and welders. If you will be TIG welding the heavy material and on bigger projects, the water-cooled torch setup may be worth considering. Remember that your welding machine will need a water cooling system. These can be expensive and this is why you may need to make your cooler.

How to Make a Water Cooler for TIG Welder

Importance of a coolant

If you will be using the TIG welders continuously, you will need a water supply to cool the torch to a temperature that you can handle comfortably. When you develop a cooling system for the TIG welding torch, you can easily protect the nozzle and electrode from melting no matter how high the temperature gets in the welding torch. This is why you may need to install a water cooling system for the TIG welder.

Source of heat for the plasma welding torch

Many people assume that the plasma cutting torch is the biggest heat source in a TIG welding system. However, the part that heats the most is the power leads, made of some flexible braided metal cables and are common found below the cooling hose that is connected to the body of the torch.

The power leads create a lot of electrical current in the small space. Since a lot of heat needs to be moved in a tiny space, they tend to generate heat continuously. This raises the need for a cooler to get rid of the heat and protect the hoses from melting. This is why coolant is necessary.

The electrode is also responsible for creating a lot of heat inside the body of the torch. The face of the electrode gets connected to a plasma arch and this means that there is a huge amount of power passing through the tiny metallic area. Therefore, you will need to protect the plasma arc and electrode from melting.

Making the water cooler

Here are the materials and steps involved in making a water cooler.

Materials needed

To make a cooler for your TIG welder, you will need the following materials:

  • Water pump(should be submersible)
  • Water container
  • Three horse clamps
  • Plastic tubing
  • Aluminum plate
  • Plumbing

Step to follow

You need to start by setting the water container close to the TIG welder and inserting the submersible pump inside.  Ensure that when you keep the cooler close to the handle of the torch and the torch code, as this will make it easier to connect the tubing to the TIG welding torch.

If you find the cooler basin location to be fine, you should detach the jacket covering the outer part of the torch cord. This exposes the gas tubing as well as the electrical conductor. When you snap the jacket completely, two copper wires will be exposed at the lower part of the handle of the torch. The copper fitting will help conductor water inside and outside the handle of the torch.


You will now need to unfold the 02.5-inch tubing before…

Αttaching one of the fitting ends to the handle of the torch and securing it with the screwdriver and hose clamp measuring a ¼ inch. After securing the tubing, run it down the torch cord’s length until it gets into the submersible pump inside the basin of the cooler. If there is any elongated tubing, you should connect it to the copper fitting at the handle of the torch.  If there will be any water running back to the cooler basin, this tubing will help to drain it. Ensure that the tubing is secured in the same way as you did in the previous step. You should cut the tubing to enable it to rest on the cooler basin.

Finally, you will have to reach the torch cord’s cover and make sure the tubing fits well inside the covering. Use fresh cool water and ensure that the basin’s top is covered with plywood. This will ensure that no debris falls into the water. You should now connect the pump with the power supply. Ensure that water is flowing and draining well. You now have your TIG cooling system ready.

To ensure that the submersible pump doesn’t burn, be sure to check the water levels every day before you start running the TIG welder. Remember that the water level can go down as a result of leakage or evaporation.


The TIG welder is among the leading welder machines. However, you need to ensure that it remains cool. You can follow the above steps to your TIG welder cooler.

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