I am part of a team working on a restoration project to bring a B-17E to flight worthy status. It requires 2024-T3 aluminum lap joint to be spot welded. The sheet metal parts are .032" each for a total thickness < .065" with a spot weld diameter of .125". These parts were originally spot welded together and new wing skins will be fabricated that require thousands of these spot welds.

Can anyone give advice on the amount of current needed to produce these welds so I can research the welder needed for the job? I have read in some places that 50,000 KVA or more and about 36,000 amps on the secondary would be needed. Any advice on welding timer controls and machine recommendations would be welcomed also. Or if you know of any consultants or equipment suppliers that could recommend new or used equipment that would work for this application.

Thanks in advance.