Stick welding cables.

Right, I'm deliberating again, I used to be indecisive but now I'm not so sure

Bought some new 25 square cable to replace my cables on the stick welder, they're silly short as they are and I need more flexibility, got a good deal on 6 meters and think that should be plenty, but..........

How do I divvy the cable up?

i like equal

Evens.

Well the work lead is usually longer than the ground lead, no need form them to be equal length

Thor1950 said:

Well the work lead is usually longer than the ground lead, no need form them to be equal length

Click to expand...

Correct.

I have mine even because it's a portable unit and having them both fairly close to the work is easier. I also try to get the earth as close to the weld as practical 'cos when 'parts' of what you're welding might still be rusty, a good connection is necessary. If I had a big enough workshop to have a dedicated workstation it might be different, but I doubt it, 'cos for what I do I'd still have to move around ..

Thor1950 said:

Well the work lead is usually longer than the ground lead, no need form them to be equal length

Click to expand...

I'm tempted to go with 1X 2mtr for the ground and 1X 4mtr for the stinger, I've migrated up to 25 from the original 16mm/sq as I am trying to mitigate amp drop through the longer cables. Got new earth clamp and stinger as well as some DIN quick release connectors as I want to try and make it easier to store and transport, really need to fit a high velocity fan to extend the duty cycle too but it's adequate for what it is and what I do with it currently, next step is to upgrade to a new inverter unit but that's a whole other ball game and I'd need to do a lot more stick welding than I do currently.

For those that are interested, all the parts arrived and as the weather was rubbish and I refuse to go out and get soaked to the skin, I decided to get it all sorted.

Take 1 stick welder.






Dismantle the casing and remove the old cables.



The new female fittings have a small lug on the insulator them to stop them turning when you fit the cables.



Fit the females and crimp some terminals on the solid ally cables off the transformer and connect them all up.





I cut the cables to give me 1X 2mtr for the earth and 1X 4mtr for the electrode holder and these are the new earth clamp and electrode holder.





I fitted a terminal on the earth lead first.



And snugged it up on the earth clamp stud.



Then fitted the male connector on the other end, this is the same for both the earth clamp and the electrode holder so won't bore you with two of the same piccies LOL



Measure the insulation that needs stripped back.



Fit the copper wrap around that will protect the cable as the allen bolt is tightened down.



Tighten it all snuggly.


Slide over the insulating rubber boot and job jobbed.



Then fit the cable on the new electrode holder.
Measure and cut back the insulation to fit inside the holder.



Slide in the copper clamping strip.



Tighten it all down, slide on the cover that doubles as the handle and job jobbed.



Fit the male spigot on the cable end and voila, all done.





Will test it out tomorrow night if the weather stays dry