Modding a ground clamp?

[Big Barn]

PCB boards are not crimp on style power cable connectors..... In industry I came out of (retired after 38 years) everything than was #14 gauge and larger was a crimp connector and no solder and we went up all the way to 750,000 CM cables.... "PROPER" crimp connector is industry wide standard....

Where most people fail with crimp on connector is the don't know proper way to crimp them, you DO NOT squeeze them in a vise or beat on them with hammer, first thing is lug (connector/terminal) has to be proper fit to wire size and then a proper indenter or circumferential crimp must be uses, also recommended to put some anti corrosion grease on cable end before crimp if connection is going to be in harsh environment... Heat shrink tubing also helps keep oxygen and moisture (corrosive perpetrators) out of crimp....

Most people are put off by wire crimping because they have had poor success for cheap auto parts crimpers.... And don't know to step up to more professional tools...

Poorest tool for crimps, if you have these, throw them away...

Suggest you get ratchet style crimpers with interchangeable dies for type of crimps you are attempting....

For large work...

Dale

Agreed! Proper tools are required for successful crimping.

 

[Big Barn]

Mark. If. You are considering quick connects I would go with the small Dinse 10-25 size which has a 3/8” pin. This would work well with your AWG 6 ground wire.

Pic of my plasma cutter with Dinse 10-25 panel plug. I upgraded the wire to 6 AWG from the smaller horrible 10 AWG that is impossible to coil up.



The larger Tweco or Dinse 35-50 plugs are unnecessarily big for your applications. IMO

 

[dragoneggs]

Not sure of the Tweco part numbers anymore for the Quik connects but you can also get Lenco LC10 for smaller cables and LC40 for the big stuff. There are likely several others out there. Good Luck and happy shopping.

yomax, I looked at the Lenco LC10 and they are rated for 4 AWG or bigger. Is there a smaller one as I am working with 6 AWG.

Mark. If. You are considering quick connects I would go with the small Dinse 10-25 size which has a 3/8 pin. This would work well with your AWG 6 ground wire.

Pic of my plasma cutter with Dinse 10-25 panel plug. I upgraded the wire to 6 AWG from the smaller horrible 10 AWG that is impossible to coil up.

View attachment 602151

The larger Tweco or Dinse 35-50 plugs are unnecessarily big for your applications. IMO

Terry, I was hoping for something in line that I could disconnect relatively close to the ground clamp so I don't have to have another full run of wire. Are there Dinse plugs for inline applications or just for panels?

 

[dragoneggs]

Also taking a look at my 45xp plasma cutter. The ground clamp is copper and rated at 200amps. There is a Dinse plug at the machine end, so I could just get another full length cable to fit a Magswitch on that unlike my 211 that is hardwired. The cable looks to be a gauge or two less than the 4 AWG on my MIG.

 

[Big Barn]

yomax, I looked at the Lenco LC10 and they are rated for 4 AWG or bigger. Is there a smaller one as I am working with 6 AWG.


Terry, I was hoping for something in line that I could disconnect relatively close to the ground clamp so I don't have to have another full run of wire. Are there Dinse plugs for inline applications or just for panels?

That’s a good idea about swapping with your plaz. Earlier models were hardwired. IF you have room on your 211 I would try to install a panel plug. Much neater installation.

Do you have the tranny 211 or the newer inverter?

35-5 - Dinze Dinse Type Welding Connectors - Cable Plug (Male) | eBay

 

[dragoneggs]

That’s a good idea about swapping with your plaz. Earlier models were hardwired. IF you have room on your 211 I would try to install a panel plug. Much neater installation.

Do you have the tranny 211 or the newer inverter?

35-5 - Dinze Dinse Type Welding Connectors - Cable Plug (Male) | eBay

Tranny... and it appears tight on first glance but I might fit just below the feed.

 

[yomax4]

yomax, I looked at the Lenco LC10 and they are rated for 4 AWG or bigger. Is there a smaller one as I am working with 6 AWG.


Terry, I was hoping for something in line that I could disconnect relatively close to the ground clamp so I don't have to have another full run of wire. Are there Dinse plugs for inline applications or just for panels?

I did the same with my plasma. Another outlet for the small Dinze connectors is Profax. They have Lenco LDC-25 connects.

 

[Ford850]

How often are you going to switch from the new mag ground to a clamp? If it's just for occasional use, can you add a small steel disk to the clamp and attach your magnet to that when needed? Or at least until you have time to figure out a better solution.

 

[Big Barn]

I find the big advantage of having a panel disconnect is being able to remove the cable and coil it up neatly when not in use.

Also makes it easy to add an extension if extra length is needed. More applicable for stick welders of course.

 

[Big Barn]

I knew I had a small Dinse panel plug and connector somewhere.




I swapped in the larger size to make the ground cables interchangeable for these two Thermal Arcs.




Yours if you want it Mark, as it is of no use to me.

 

[Big Barn]

Here’s an 800 amp switchable mag ground clamp.

Magswitch 8 Amp Ground Clamp | Mag-Tools

 

[dragoneggs]

Here’s an 800 amp switchable mag ground clamp.

Magswitch 8 Amp Ground Clamp | Mag-Tools

Yep that is a bad boy... too big for my needs!

 

[fried1765]

I would do that if you can稚 find the proper terminal lug easily. A proper cable crimping tool should then be used instead of just squishing it in a vise.

^^^^^^^proper crimping tool!
NO VISE CRIMPING!

 

[fried1765]

Crimping (properly at least) is superior to soldering. As odd as it sounds it's quite true. When you solder stranded wire solder wicks up the strands & fuses them solid. You then end up with flexibility issues. Chances of damaging insulation is high as well. In the event of any issues, wiring heats up. That doesnt phase crimps much, but soldered connections can fail catastrophically in those situations.

All car & aircraft wiring harnesses are crimped. If you have the right crimper an idiot can get a good crimp that can easily be inspected. Soldering takes skill & in blind lugs like you are talking about they cant be inspected.

There are dozens of cheap hydraulic crimpers out there. Goplus 16 Ton Hydraulic Wire Crimper Battery Cable Lug Terminal Crimping Tool w/ 11 Dies https://www.amazon.com/dp/B00ZA2P3XM/ref=cm_sw_r_cp_apa_i_h2iWCbYH1SJN6 is a random one off Amazon. I'm sure its identical to the others there or the one from Harbor Freight. I picked up on off Amazon for a pile of big Anderson connectors. Its a cheap tool & a little fiddly to use, but great bang for the buck.

I'm sure you could make soldering work, lots of people have, but it's an inferior technique for most modern applications.

Also, get the right sized lug for your wire & terminal. You can use a copper pipe as a shim or fold over the wire, but that severely weakens the connection.

^^^^^ what he said!

 

[Big Barn]

^^^^^^^proper crimping tool!
NO VISE CRIMPING!

You are right! The tool I used puts a dent across the splice and is better than squishing the whole thing in the vise.

I agree a proper crimper would make the best connection.

 

[dragoneggs]

I absolutely love how a simple thread on a ground clamp mod can yield so much valuable info... thanks guys!

 

[WranglerX]

I absolutely love how a simple thread on a ground clamp mod can yield so much valuable info... thanks guys!

Shows the difference between amateurs and professionals...

Dale