HOLY CRÄP!
I've re-wired my electrolysis rig (see pic) with some proper crimp terminals and an aluminum wheel as heat sink (WAY overkill). I decided to make my little welder pseudo-DC while I was at it. I can connect the welding cables on the AC side or the DC side of the rectifier. No choke or capacitor to filter the rectified voltage yet, we'll see if I get there.
Anyway, I never cleaned off the one control arm I ran last week but I decided to do that with the other one. There was some loose rust, old road muck and some rust protectant to scrape off. Once I put this one in, the hum of the welder increased considerably, suggesting a much larger current.
After a while, the bath looked seriously like a lasagna. When I turned the work piece over to work on the other side and connected the cable, some serious sparking occured and there was a sharp BANG and a flash. I guess the foam was full of hydrogen gas. My ears are still ringing. It was about as loud as a small caliber pistol.
I almost soiled myself ...
They really aren't joking about the whole 'well ventilated area' deal ...
Here's what the bath has done for the first LCA so far: