A simple and inexpensive device to make electric or gas‐welded butt‐join thermocouples is described. It allows for junction bead size control by means of a spring‐loaded moveable block with adjustable travel. The device has been successfully tested with thermocouple wire diameters of 125, 250, and 375 &mgr;m and should also be able to accommodate smaller and larger wires with very minor modifications.