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[bobf <bobford79 AT yahoo.com>]

Folks were talking about welders a while back.  This guy says he can build 
(and has a how-to video on the webpage for free) a welder from thrown out 
microwave ovens?  Don can probably speak of the safety aspect, I know that 
working microwave ovens go for a dollar or two at yeard salwes, and when 
people put out their quarterly curbside trash, they are all over the place 
for free.  Anyway..................

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http://www.instructables.com/id/Build-a-Microwave-Transformer-Homemade-Welder/

introBuild a Microwave Transformer Homemade Stick/Arc Welder
I had no idea making a DIY welder would be so easy to do. And, it's pretty 
much FREE! 

Additionally, the stick welder you get is definitely better than anycheap 
commercial welder you can buy.
Why is this homemade thing better than something you can buy? Because when 
you factor in shipping and labor and the little bit of retail markup - the 
companies that make typical cheap buzz boxes will skimp on copper as much as 
possible. Whereas you can use enough copper in this to make something really 
juicy, and still spend less, to nothing, compared to a store-bought arc 
welder. 

So here's what you need to build a welder:
- Two beat up old microwaves
- Some 10 gauge wire
- Wire nuts

People throw out microwaves all the time, if you keep your eyes on the curbs.
Or, you can get microwaves at the local thrift store for $10 each.
Try the warehouse that processes donations - they have to pay to get rid of 
tons of broken ones.

Stuff you need for welding:
- Welding helmet ($16 and up)
- Welding rods ($6) 
- Vice grip or purpose-built electrode holder ($6 for either)
- C clamp for grounding clamp
- Gloves
- Thick nonflammable (leather) clothing that will cover your arms

Disclaimer: High Voltage ELECTRICITY and lots of CURRENT! Heat, 
electrocution, and DANGER! You could die and you could go blind.

That said, try this at home!

See this for a lot of welding safety tips

Here are the really good how-tos that this project is informed by:
build a 70 amp welder
the tiny tim welder by tim williams
home made welding machine (via afrigadget)

Dan Hartman's how-to is good for reference, too.

And here's the quickest way to make a DC welder with a bunch of 12 volt 
batteries.