Skip to main content

DIY: 5-Steps in Making your Own Power Resistor

Before making your own power resistor, you will need to know first its components, its uses and ultimately, how it works.

What is a power resistor?

Power resistors are devised to hold large amounts of power. They have a power rating of at least 5 watts. Their components are made from materials with high conductivity, which makes cooling more efficient. They are often partnered with heat sinks which enable them to dissipate the high amount of power. Power resistors have different types; namely,

  1. Wirewound resistors

These resistors are built to withstand high temperatures, up to 450 ℃. They are formed by winding a metal around a ceramic, fiberglass or plastic.  Metal caps and metallic leads are then attached to the end of the winding. For protection, the body of the device will be coated with a non-conductive paint, enamel or plastic.

2.   Grid resistors

These resistors can withstand currents of over 500 amperes. They are large matrices of metal strips connected between two electrodes. Large sized grid resistors can be as big as a refrigerator. They are commonly used as brake resistors and load banks for railroad vehicles and load testing of generators.


3. Chip/SMD Resistors

Chip resistors are those which look like integrated circuit chips made from many different materials, such as pressed carbon, ceramics and metal foil. SMD resistors, on the other hand, are smaller in form. The resistor consists of a metal oxide film deposited onto a ceramic substrate. The thickness and length of film determine the resistance. With appropriate cooling, these resistors can dissipate no more than a few watts.

4. Water resistors

These resistors consist of tubes filled with a saline solution with an electrode at both ends. The water in the tubes provides a large heat capacity which allows a high power dissipation.


5. Liquid Rheostats

Also called as salt water rheostats, resistance in this type of variable resistor is controlled by submerging the electrodes into a saline solution. They may be raised or lowered by adjusting the electrode position inside the liquid. Although they are slightly outdated, they are still used in some diesel generators.


What are its general uses?

Generally, power resistors are used to convert large amounts of energy into heat. They can be used as engine breakers for locomotives and trams, as they offer controlled braking power without wearing the parts. Load banks are used to load-test generators, turbines, and battery UPS Systems. It can withstand and dissipate as much as 6 megawatts of power. They can also be used in power grounding of Y-connected generators and in medium-voltage AC distribution systems. With the help of these resistors, grounding fault will be much easier to locate because the possible fault locations are only of a limited number.

5-steps to making your own power resistor

After learning the basic components and uses of power resistors, you are now ready to make your own. Listed below are 5 easy steps you can use:

  1. Get one old high wattage resistor. Destroy it and take the high resisting wire of your desired length.

  2. Prepare some copper wires and use it as a 


  1. You will need a jointing filler to create the mass for coating. This is essential to protect the resistor wire from oxidation and to provide heat transfer from the wire to the environment.

  2. Prepare a small piece of tin to create the mold.

  3. Dry and see results.

Power resistors can be a complicated case but it is widely useful in today’s technology. The basic information listed above can serve as your guide into understanding more of these resistors.


Popular posts from this blog

Copycat Boston Pizza's Bandera Bread

Have you ever had a craving for something but then once you looked at it you realized, I can make that myself for next to nothing? That's how I felt last night I thought about ordering in some food but then realized I really don't want to spend any money. I really wanted pizza bread from Boston Pizza. So I recreated it and oh my goodness was it ever good. Try some of these great recipes too!  Pizza Bread Dough 1 cup warm water 1 tsp instant yeast 1 tsp sugar 2 cups flour  Seasoning 1 tbsp melted butter 1 tsp garlic powder 1 tsp onion salt 1 tsp parsley 1 tsp rosemary 1 tsp basil 1 tsp oregano 1/2 tsp sugar 1. Combine the water, yeast, and 1 tsp of sugar in the mixing bowl and let stand for 5 minutes. Add the flour and salt and mix until a ball of dough forms. Roll ball onto a floured counter top and knead for a couple minutes.  2. Put dough in an oiled bowl and let rise for 30 mins in a warm place with a clean cloth draped over top. While your doug

Affordable Ways To Make Your Home Look Luxurious

How do they do it? Professional designers seem to pull it off so effortlessly, but how will you make your home look more luxurious? You could just employ a professional or you can personally undertake the task of transforming your home into a place of luxury on a budget. In order to save money on your purchases, be creative and vigilant in your pursuit for the perfect style. Follow our budget-friendly ways for making your home a vision of luxury. Think it through, choose a style Luxury look isn’t enough to go on, so before you start shopping and wasting your money on furniture and decorations you might not even use in the end, first do some research. Go online and do some window shopping and find which style is more to your liking . An elegant Victorian style or something more modern and chic? Don’t get me wrong, you may want to mix and match, but before you commit by buying anything, consider what look you are going for. White is the color of elegance Choosing white as yo

DIY Table Revamp - Guest Post

Hi all! I'm Tiffany from This Motherhood is Brought to You by Xanax and I am so excited to be a part of the Guest Post Swap and to be Amanda's swap partner! I love love love her idea on how to make indoor snowballs with egg cartons. I am definitely going to have to try that with my kiddos since my smallest one has decided that it has to snow for Christmas. Poor baby doesn't know snow is hard to come by in Alabama :( For my guest post I wanted to share a little DIY with you guys that involves duct tape! A few months ago my daughter's little chair that goes with her table she sits at every day tore and she made it worse by pulling all of the stuffing out of the seat! What started out as a quick fix turned into a great idea. She loved her seat so much that she has now decided that her table has look cool too so being the smarty pants that she is, she tore her table!