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Joining #6 wire.

milkovich

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I'm trying to add another welding outlet and using #6 (per code). How do I splice the circuit and join three #6 wire ends.

The largest wire nut only joins 2 #6 wires.:dunno:
 
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malibu101

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Search for a "split bolt connector" also known as a "bug".

With the proper tool, die, and connector Crimping is an option too but that's not practical to buy for the 1-time use.

Look around at Ilsco wiring products for something like this-http://ebusiness.ilsco.com/webapp/wcs/stores/servlet/CategoryDisplay?storeId=10001&langId=-1&catalogId=1&categoryId=167

I hope your box is big enough.

EDIT- Now that I think about it- can a bug be used for 3 wires?
 
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bluesman2a

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Malibu is correct. I JUST finished this with exactly the same materials, for the same setup (one #6 feeder for two welding outlets).

Home Depot has everything you need. Get the COPPER split bolt connectors (forgot the size, but 3 quantity #6 wires was no problem). They have a variety of sizes, they are typically near the zip ties in with the electrical supplies, in plastic hanging bags. You will need 3 of these.

You will also need the padded double-sided electrical tape (the really thick stuff). Forgot the number/designation for this, but it's the only double-sided stuff I saw.

Last but not least, you will NOT be able to do all this in a 4" box easily (not even the deep ones). I bought a larger 6" X 6" box that works very well.

Process:

1) get all three wires into the box and strip appropriately (about 1/2")
2) get split bolts ready (have appropriate wrenches close).
3) insert wires into split for best fit. On one I did them all from one side so the wires were bundled. On another, I needed a flatter configuration so I did the top from the left, the middle from the right, and the bottom from the left as well. Go with what works best for your situation.
4) Wrap entire exposed mass in the two-sided electrical tape, this creates a cushion and insulates the split itself.
5) The two sided stuff is sticky, so finish it all off with a coating of normal electrical tape.
 
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milkovich

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A friend of mine that does a lot of electric said "bug" and I couldn't exactly google that. "Split Bolt Connector" I can wrap my mind around. Thanks Malibu.

I didn't think of fitting it all in the box, good catch Bluesman! Looks like it's another trip to Lowe's tonight.

Thanks for the help guys!
 

Bevis

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Moore Haven, Florida
I wished i would have seen this thread before going to Home Depot this morning...Thanks for the info there bluesman, it will come in handy.
 

bluesman2a

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No problem.

Also FYI, HD has a pretty good deal on #6 prepackaged. I think it's a 125' roll for $130ish if I remember correctly.

Ideally I would have put all my welding outlets onto completely separate lines, but with some of the longer runs in my shop and the cost of wire, it was more cost effective to have more PLUGS in more places, for convenience, than have ones where I could run multiple machines at the same time.
 

Ggg

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N.W. IL.
A bug for #6 isn't very big so be careful on how much you tighten it, It is easy to strip the nut on the smaller ones. If you can't find the padded tape no big deal just use a lot of good quality electrical tape, afterall each wrap of regular ele. tape is rated for 600V.
 

Ign

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Butte Peak ND
If you're running surface mount w/conduit, you can fit it all in a deep box if you also use the raised covers for the 220 recep. The covers are hit and miss at Home Desperate, might have to go to a real electrical supply.
 

Junkman

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Northeastern CT
Split bolts are old school. Polaris or Burndy Insulated Taps are the way to go now.

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Junkman

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Damn..... that is a slick looking way to make it simple. Can you come off the wire that goes to the breaker and hook two more wires to that inside the breaker box? Sure beats the knob and tube stuff in my barn!!!:lol_hitti
 

malibu101

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I agree-I showed the Ilsco version in my first post. They are MUCH easier than bugs AND they're reusable without having to gnaw through vulcanizing tape on a bug.
 
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milkovich

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Oct 15, 2007
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Akron Ohio
We're going to try the polaris grey series (for stranded wire). Looks like a more elegant solution than the bug especially considering my tendency to overtorque fasteners plus the 4x4 box is already up and might save a bit more work on the ceiling.

Thanks!
John
 

bluesman2a

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Atlanta, Ga.
Those polaris fasteners are COOL.... didn't know about them. If I ever have to un-do or do another of these, you can BET that's what I'll be using!
 

VDubJoe

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Jan 22, 2006
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New Port Richey , Fl
All we use now on all of our ug taps now is the Burndy. They come in any size and hole options. Beat the heck out of bugs and ser-ends.

Joe
 
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