Cable Reels for Welding Trailer

MikeIA · Aug 16, 2005

Just for fun I called Meridian Labs and asked about the cost of their MC-250 rotary contacts. (250 amps, single conductor)

$1900 each /forums/images/graemlins/shocked.gif

The pleasant fellow on the other end of the line assured me that they are very nice.

Gravy · Aug 16, 2005

Gary,

A lot depends on how often you will be using it. If the use will be infrequent, and you're...ummm..."thrifty" like me, I can think of a simple approach.

Get a cheap hose reel. Wind the cables with the inside ends hanging out a bit. Use appropriate quick connectors. Unwind the cables as far as you might need them, then connect to the welder and get to work. Unplug from the welder before rewinding.

If you need to use it a lot, you're probably better off buying whatever the pros use.

Gravy

BobG_in_VA · Aug 16, 2005

Anyone know what happens when you put a high amperage/voltage wire in a perfect/near perfect circle???? thats why real welding trucks don't use the air hose windups, but mearly drape them in a sort of an "oval". That's all I will say but you won't catch me using a circular welding cable holder for my Trailblazer. BobG in VA

fractal · Aug 17, 2005

( Anyone know what happens when you put a high amperage/voltage wire in a perfect/near perfect circle???? thats why real welding trucks don't use the air hose windups, but mearly drape them in a sort of an "oval". That's all I will say but you won't catch me using a circular welding cable holder for my Trailblazer. BobG in VA )

I am even worse. I wont' use an extension cord on a cord reel. I always take the entire cord off the reel and lay it on the ground, not perfectly coiled. The pattern is not as important as the spacing between the wires. A tightly wound coil of wire on a cord reel is a disaster waiting to happen.

And yes, I have seen melted gobs of wire and insulation on "cord reels". Just not mine.

bobodu · Aug 17, 2005

I fully agree with unwinding the extension cord all the way!!
Can't get the wife to understand...have taken to winding the cord with the male end first.

GaryBDavis · Aug 17, 2005

I'm guessing you guys are referring to the heat build up that a tightly wound cable can generate. One of the welding cable reel manufacturers had a note in their literature saying you should always unreel all the cable to prevent heat build up.

For the cable itself, I found a USA manufacturer that will sell directly to the customer. I'm getting 200 feet of 1/0 shipped to my door for less than $250. They are including my name on the printing stripe. They were even kind enough to send me a sample to check out before I ordered.

The more I think about it, the more I think I'm just going to make some ovals to manually wrap my cables on. Either that or just store them in the tool box.

MikeIA · Aug 17, 2005

( I'm guessing you guys are referring to the heat build up that a tightly wound cable can generate. One of the welding cable reel manufacturers had a note in their literature saying you should always unreel all the cable to prevent heat build up )

Also what is being referred to is the inductance created by having cable carrying high current coiled in a circle. I think you can avoid it somewhat by coiling the cable in your toolbox in a "figure eight" pattern ( also avoids introducing a twist in the cable so that it uncoils neatly)

GaryBDavis · Aug 17, 2005

That and it probably makes for a good electro-magnet. I do have a thing for rolling up my cables nice and neat. I have several nicknames for being like that. No one can help me put up my tools because everything has to be put back just right - especially the hoses and cables.

My new 1/0 welding cables come in tomorrow and I'll play with them to see if I like the way they roll up manually. If they are as nice and flexible as I think they will be, I'll probably just punt on the reels.

GaryBDavis · Aug 17, 2005

Whether I decide to use cable reels or not, I’d like some advice about storing the cables and hoses in or outside of a tool box. Most of the farmer’s welding trailers around here have simple hose and cable racks to manually wind up the cables on. Although I’ll be storing the welding trailer in a barn, it seems the cables and hoses would last longer if they were inside a tool box. I can make whatever size I need. I was thinking of a vertical cabinet with a front access door – kind of like my old school gym locker.

Decision, decisions…

One of the funnier/sadder things I’ve seen was a welding trailer going down the road with about 50 feet of a lead dragging the ground. The rod holder or ground clamp had long since disappeared and a frayed cable danced around on the pavement. A cabinet would help prevent that.