Using larger welding cable plugs on a smaller welder

[iwoodsman]

I acquired a stick holder and ground clamp that seemed more robust than the ones that came with my little 110v 135A welder. A lot more visible copper. I was ignorant that there were different sizes of this shape of plug. I am having trouble determining at online stores if there is a simple adapter for my new big plug to fit my smaller socket, or if I’m supposed to do surgery on the welder’s sockets, or if I should just realize that the big plug is for big welders and using it is a bad idea.
In the pic, the new cable is the big one. It’s labelled dkj35-50 while my small one is a dkj10-25. Anyone got a clue for me?

 

[T444e]

I would think an adapter would be available, but I am not familiar with DKJ connectors. I'm only familiar with Dinse and Tweco. Otherwise you be able to change the connectors on the stinger and ground to match the machine. I've done that before.

 

[yatg]

I would replace the connectors on the machine with -50s

https://www.amazon.com/RIVERWELD-Welding-Connector-plug-DKJ35-50-DKZ35-50/dp/B07MZ7LLB6?tag=atomicindus08-20

 

[The Cobbler]

replace the connector on the new cable with the proper size

 

[T444e]

replace the connector on the new cable with the proper size

I wouldn't bother replacing the cable as long as it fits the new connector. Nothing wrong with a larger lead.

 

[iwoodsman]

I would replace the connectors on the machine with -50s

https://www.amazon.com/RIVERWELD-Welding-Connector-plug-DKJ35-50-DKZ35-50/dp/B07MZ7LLB6?tag=atomicindus08-20

Does using larger connectors have any negative consequences, especially with a weaker machine?

 

[jack stand]

The factory leads are probably sufficient and I wouldn't bother with any extreme modification just to accommodate bigger leads. Your welder is only good for it's rated output regardless of how heavy the leads might be above the original.

 

[iwoodsman]

Thanks all. I will replace either the plugs or sockets, depending on how easy it is to get in that part of the case.

 

[cvairwerks]

Probably easier to make up an adapter cable.

 

[PCustoms]

Probably easier to make up an adapter cable.

Not as cheap as he will need 2 sets.

I'd cut the ends off, save them in a drawer, and put the right size on.

 

[MJD1]

Lenco 05335 adapters. Available from Amazon

 

[kctgb]

If your cables are in good condition replace the connectors. Have you seen the price of new cables lately? Dinse connectors come in two common sizes. I believe the 10-25 is 25 mm dinse style connector, and the 50 is 50mm connector. This is a good reference for size.