Welding leads 101

[A_Pmech]

I've been swamped with work lately and haven't had a lot of time to post. But, while setting up my new Miller Dialarc, I came across a handy idea I thought I'd pass along on how to build a modular welding lead.

I found this method on a welding message board while looking for a welding lead ampacity chart. A poster, who is a pipeline welder, made a suggestion on how to set up modular welding leads with quick-connects which is highly versatile. I liked it enough to do the same with my welder.

For reference, this is a welding lead quick connect. There are several styles, but this type manufactured by Tweco appears to be one of the more common styles:

Here's how the system works:

1) Rather than using crimp-on lugs to connects the leads to the welding machine, use quick-connect lugs. In this case, I used Tweco part# 1-AF lugs:

2) Set up your welding leads in equal lengths of 25', 50', or 100' and install a male quick connect on one end and a female quick connect on the other, just like an extension cord. In my case, I chose lengths of 50' and I used Tweco male-female lead connector kits part# 1-MPC:

3) Make 10' leads for your stinger and ground clamp and install male quick connects on the end of each lead. The Tweco male-male kit is part# 1-MPC-1.

By using this system you can connect your stinger and ground clamp directly to the lugs on your welder. Or, you can connect one or more sections of lead between your stinger or ground clamp and the welder, up to the ampacity limitations of the cable size and length.

By breaking the leads down into sections you don't have to wrestle with a hundred pounds of lead when you only need to work a few feet from the machine. It also alleviates the need for an expensive lead spool because the broken down sections are much easier to coil and store.

 

[metaleltr]

I like it! Which welding board was it on?

 

[OccupantRJ]

That's the only way to fly. I have had my welding leads modular for about 32 years now, and have loved every time I have to weld. I also had a lead run through the attic of my previous shop with a drop hanging near the middle of the room, to allow me to connect up in the middle of the shop when building trailers without having leads strung all over the place. For the ground, I have a jumper lead with spring clamps on each end. I first hook the ground lead from the welder to my welding table, then jumper from the other side of the 8 foot table to the project with the ground jumper lead. This also lets me weld in the middle of the floor or on the table without switching ground leads around.

 

[JayL]

What cable size are you using?

I think I should have used 1MPC instead of 2MPC (with 1/0 cabling ) for my setup since I don't go over 200A on the stick welder.

tks

 

[A_Pmech]

I like it! Which welding board was it on?

I think I found it somewhere on Weldingweb, but I honestly don't remember. I just latched onto the idea and ran with it.

That's the only way to fly. I have had my welding leads modular for about 32 years now, and have loved every time I have to weld.

I figured it wasn't a new idea, but it's not something I've seen very often. Glad to know you like it, I have a feeling I will too!

What cable size are you using?

I think I should have used 1MPC instead of 2MPC (with 1/0 cabling ) for my setup since I don't go over 200A on the stick welder.

I'm using #1 cable.

I believe the 1MPC connectors are usable to #1 cable. For 1/0 you need the 2MPC connectors IIRC. (I don't have the catalog in front of me.)

 

[littletoes]

Well....that is the only way I'd ever seen it done....

Oh yea....that's right, I'm a UA Steamfitter! That's the only way we do it!

 

[MattT]

Aside from what's already been mentioned another advantage of going modular is it lets you use a lighter stinger cable. Say your 120' circuit requires #1 cable. Sounds a little on the light side for a dialarc BTW. Anyways dropping down to #2 on the 10' stinger lead won't hurt anything and gives you better handling and less fatigue.

 

[machine_punk]

That is a fabulous execution of a great idea. Did you just buy a whole reel of the size cable you needed and cut it up yourself?

You've mentioned that you have a lot of requests for welding lately and it looks like you are ramping up to meet that need. Did you weld before this, or are you learning now, to meet your business needs?

M_P

 

[trackwelder]

Thats the only way to set cables up. I have several different electrode holders on 10' leads to choose from depending on the job. The suitcase feeder and airarc also have quick connects.

 

[bad_idea]

I work in ship repair and that is the only way they do welding leads in the shipyard. I didn't think there was any other way to do it (not being sarcastic, just honest). At times we have strung close to 200' of lead. Sometimes we get lucky and there is a 440 hookup near where we are working and just plug the stinger into the machine.

Argon hoses and O/A hoses also get quick connects at fire boundaries.

 

[A_Pmech]

Oh yea....that's right, I'm a UA Steamfitter! That's the only way we do it!

That would explain why that's the only way you've seen it done.

Aside from what's already been mentioned another advantage of going modular is it lets you use a lighter stinger cable. Say your 120' circuit requires #1 cable. Sounds a little on the light side for a dialarc BTW. Anyways dropping down to #2 on the 10' stinger lead won't hurt anything and gives you better handling and less fatigue.

Interesting idea on the smaller cable.

I considered going to 1/0 or even 2/0, but I can run the machine at capacity with the length of lead I have, which is about 3x longer than I've ever had. If I need to go out farther I can still burn some 1/8" 6011 at the end of the driveway. That's more than sufficient for my needs.

That is a fabulous execution of a great idea. Did you just buy a whole reel of the size cable you needed and cut it up yourself?

You've mentioned that you have a lot of requests for welding lately and it looks like you are ramping up to meet that need. Did you weld before this, or are you learning now, to meet your business needs?

Yes, I bought half a short reel, 125'.

I've been welding since grade school and I'm entirely self-taught through careful study. I studied several books and applied what I learned along with numerous handbooks and manuals put out by the AWS of interest to me.

The main books I use are:

"Welding: Principles and Practices" by Raymond Sacks

"The Procedure Handbook of Arc Welding" 13th Edition, The Lincoln Electric Company

"Modern Welding" by Althouse, Turnquist, Bowditch

Once my welding setup is complete I'm going to take on a more intensive level of study to bring everything up to muster.

I've learned enough that, should the need ever arise, I can set up a code-compliant shop and would be capable of passing the necessary certification tests with some practice. Regardless, I have no interest in solely welding for a living, it is part of a larger package I can offer my customers.

 

[Amitygravel]

Hey John !

Modern Welding was my high school text book for welding some 32 years ago.
I got a copy of it years ago but can't fid it. Where did you get yours ?

Craig

 

[A_Pmech]

Hey John !

Modern Welding was my high school text book for welding some 32 years ago.
I got a copy of it years ago but can't fid it. Where did you get yours ?

Craig

Hi Craig,

I found my copy at a used bookstore in California.

Ebay or Amazon would be a good place to look for a used copy. Although, I find "Welding: Principles and Practice" to be a better book for the study of the SMAW process. If you follow the lessons and practice them to perfection you ought to be able to pass any structural welding test. The section on pipe welding is a little lacking, but that's not of much interest to me.

 

[JASTECH]

+1 That is a fabulous execution of a great idea!

I need to implament this modular system you showed us too. I can't carry my 100' stinger lead around anymore in my new condition either. Plus I have not welded sence being on oxygen 24/7, kinda afraid to, am I stupid or is their a way to do it?

Thanks, JASTECH

 

[cundifc]

Where can I get those quick connects? This set is awesome.

 

[sberry]

I also have my shop stick machine connected in to a "loom" with a lead strung on the wall to remote location. Benches, welding booth 2 ground leads with clamps and 2 stingers connected to one machine. It makes for relatively flip of the switch service on the shop floor, at benches or outdoor on apron. ****, need to reboot for pics maybe?

 

[zkling]

Where can I get those quick connects? This set is awesome.

Check your local welding shop, should be under $20 for a set.

I did this to my syncrowave a while back. It is the only way to go IMHO. Really hate to have 50' of lead coiled up when you are only using 5' to get to the welding table.

 

[larry_g]

Interesting idea on the smaller cable.

I considered going to 1/0 or even 2/0, but I can run the machine at capacity with the length of lead I have, which is about 3x longer than I've ever had. If I need to go out farther I can still burn some 1/8" 6011 at the end of the driveway. That's more than sufficient for my needs.



.

One of the ideas on the 10' stinger wire is to have a couple of them. Smaller guage to do lighter work and heavy when you need it.


lg
no neat sig line

 

[sberry]

Number 1 will run a 1/8 6011 as far as practical.

 

[cundifc]

Okay so I need a little more clarification. Currently I have 25 foot leads. If I made a set of 10 foot leads I would just need to hook them together with a male and a female quick connect? And I would need to get a set of studs to hook to the machine and another set of male ends?

 

[sberry]

They are plumbed just like extension cords. Female from machine, leads are male female.

 

[PCO6]

I also have my shop stick machine connected in to a "loom" with a lead strung on the wall to remote location. Benches, welding booth 2 ground leads with clamps and 2 stingers connected to one machine. It makes for relatively flip of the switch service on the shop floor, at benches or outdoor on apron. ****, need to reboot for pics maybe?

sberry - Sorry to get off topic but can you explain what the white "cabinet" on the right side of the picture you provided is used for? Just curious. Thanks.

 

[shocksandstrutz]

its a welding cabinet.....i saw it on another post........little late, im sure you read about it

 

[Major Ramifications]

If any of you guys are interested, I have some of these quick connectors (used) at home. Send me a PM and I'll dig them up and come up with a cheap price.

 

[sberry]

Really hate to have 50' of lead coiled up when you are only using 5' to get to the welding table.

I see someone mentioned 25 ft etc and here is my take,, and I have done or seen this done about every way it can be. I have stingers on 10 ft but any new I rig has a stinger and ground adequate for most work in one piece, a dialarc might have 50 ft stinger and 50 ft ground and a connect like the OP shown,,, and a male on the lead end. This reduces connector cost and still allows a section to be added if needed. I don't mind having 50 ft hung up and use 5, the machine really doesn't know the difference.

Yes,, the white thing is a ventilated welding booth made from washer and dryer jackets and dryer fan.