Ken:
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I've got a 1 ohm, 10 watt unit I can try. Seems like a small wire for such large current though.
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10 watt won't be enough for many amps. In a worst case scenario, you might be dropping as much as 2-3 volts across that resistor, and passing 15 amps through it. That works out to 45 watts.
At best, it's only enough for @ 10 amps, if you can keep the voltage drop <= 1 volt.
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I'm still dumbfounded on how to get a better idea of the surface areas involved.
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It's a tough one isn't it! I've resigned myself to taking good measurements of all the various sides of a part, and pluggin them into a spreadsheet. That gets me close enough, but it's very time consuming.
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I've used the bath to plate a plethora of smaller parts yesterday with no problems at all! Large parts are a definite learning experience for me!
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Then your electrolyte is good! It's got to be a surface area calculation, anode area and/or separation, or power problem (too much or too little)!
Sean