What size welding cable?

[patrick_g]

Mike, What a deal! Lucky you! Nicks in the insulation are easy to fix so they don't propagate cracks when the cables flex. Get some heat shrink insulation that will slide over the cable and use a heat gun to shrink it. It makes a pretty waterproof repair and prevents cracks from forming/propagating in the damaged areas.

I don't have nice long leads like you so I bought a used industrial extension cord that will easily supply 50 amps at 100 feet. I cut it into two pieces, one about 33+ feet and the other 66+ and put HD 250 volt male and female connectors on the pieces. I can run my Lincoln tombstone on either piece or both together. I have mounted the buzz box to an old dolly I upgraded with larger wheels so I can take the welding machine to the work and use the stock leads. The extension cords are way lighter than equal length HD welding leads and I have the welding controls right there near the work instead of way off somewhere else.

Still I need to get some longer leads as some projects are too big to reach without moving the equipment cart around.

Pat

 

[MikesTractor]

Pat

I know, it was a great deal. I tried to pay him for the cable, but he kept bringing up the times that I've done little things on his tractors and not charged him for them.

I've already taken care of the nicks, as you said, shrink wrap did the trick. If my buddy hadn't come up with the cable, I wouldn't have cables this long. I would probably have done something similar to what you did. Since I put the longer cables on my welder, I probably haven't pulled off more than 25 or 30 feet, but it's nice to know it's there if you need it.

My welder isn't on wheels, I put it up on a stand about 2 feet off the floor. It makes the controls a little easier to get to.

I'm in the process of building a cart for my wire welder with larger tires so it will roll across the shop lot (read gravel). The tires are salvaged from an old lawn mower. I'll post some pics of the cart soon.

Mike

 

[patrick_g]

Mike, A note of caution... Welding cables get hot when amped up heavily. Coiling up the excess length concentrates the heat and will potentially melt the insulation at a much much lower amperage than would be required for cables not coiled up. Now if the air flow from your machines fan just happens to blow across the coiled up leads then lucky you, they won't overheat so easily.

Pat

 

[MikesTractor]

Pat,
Thanks for the tip. I never really thought about the heat in the cables. I haven't really done any serious welding with the new welder, just played with it a little when I first got it. I'll make sure to watch out for the heat.

Mike

 

[sandman2234]

I have a bunch of 2/0 welding lead that is too big for me to use, unless I use a smaller stinger lead on the end of it. If the price of scrap copper keeps going up it may get sold.
David from jax

 

[patrick_g]

Pat,
I'll make sure to watch out for the heat.

Mike

Mike, Given the cross section of the cables, unless it is hot weather and or you weld at high power for a long time you may not experience a problem.

Same story for long extension cords wound up on the convenient reels. If used near maximum power levels while wrapped up they can overheat, especially on a hot day.

The insulation is OK for max power when the cables are NOT ROLLED UP and the ambient temp specs are not surpassed.

Pat