Thunderbolt - extending leads

[nnn0rau]

I have a generic question regarding the 300/200 Thunderbolt. I want to extend my work & ground leads somewhere around thirty to forty feet each. My local weld supply folks have offered me a competitive price for some 1/0, however he has to order it. Will the Thunderbolt be receptive to this size of cable (thru the panel and its subsequent hookup)? Are there any concerns that I should be aware of? Can I use the existing cable attached to the new cable as stingers? Will this affect my warrenty?

Thanks for any advice!!!
Russ

[migmaniac70]

Just get some tweco twistlock connectors put one on existing cable and one on new cable twist them together and you're good to go. Easy as pie.

[Sberry]

Yes, the easiest way would be to just cut them off about a foot out and add connectors. I am not sure what you are welding but you wouldnt need to go to 1/0, you could go all the way down to number 2 or if he has number 1 in stock that would be more than plenty for that machine.

[nnn0rau]

thx

Thanks... The price will be better for the #1. The connectors are not cheap so I am considering just swapping our the old versus new cable for now. Since I am only going out 35' each way, if I want to add the stingers later, I will than purchase the connectors and... I should still be safe with the overall circuit length.
Appreciate everyones response!
thx,
Russ

[DDA52]

I'd get the connectors. They are cheaper now than later anyway. It will give you more flexibility in the long run. I have an older T'bolt with the plug in leads and I still use the connectors. I used the same size connectors as on my truck. That way when I want bigger leads, I grab a section or two off the truck and plug them in. Works very well. FWIW, I've run almost 200' of #1 and 1/0 off the T'bolt.

The #2 will be fine. You probably wouldn't like dragging 1/0 around. #1 is the heaviest you'd need with short leads.

[nnn0rau]

thanks

Very good sir… I guess it only costs a little more to do it right the first time. Besides, the connectors are not apt to get any less expensive over time. Sincerely appreciate the foresight.
Thx,
Russ

[DDA52]

FWIW, I use a #1 Tweco connector. The Lenco's always seemed to come apart on me at very bad times. I used to do a ton of multi-story work. When the leads run straight up, sometines a couple of hundred feet, the last thing you want is a connector coming apart. They tend to explode when they come apart under load! If you don't do any of that kind of work, the Lenco's might do you fine. Just don't get a El Cheapo from HF or something equal to that. Get a name brand connector. Things can break on them. ( screws, lugs, insulators etc) If you get the good ones, chances are parts will be easy to find down the road. I still can replace anything on my Twecos...and some are 20+ years old!

[nnn0rau]

When I looked it up, it was obvious that some connectors were more expensive than others, per their nomenclature -for essentually the same function... Thats why I mentioned that I thought they were kinda expensive in my prior post. I always TRY to purchase the best. My partner has told me that I research things to death before I buy ;-) I want the best, thats why I have replaced all of my old & ancient stuff with MILLER. What you have now told me confirms their justification for the price differance. I'll heed your word & will make those quality connectors part of the overall project.
THANKS!

[DDA52]

You're welcome. I have been told the same thing as regards research.

Here is the connector I use: http://www.ramweldingsupply.com/prod...iew.mcic?s=592

[Sberry]

Use anti seize sauce on the bolts and little screws to assemble the connectors too, it allows you to get them apart later.

[DDA52]

Use anti seize sauce on the bolts and little screws to assemble the connectors too, it allows you to get them apart later.

Cary
That's a good idea. The reason I lost the screws is from arcing. T'ain't much left after one hit. It hasn't been a problem for at least 6 years. With the Bobus down, wasn't much weld action on metal decks! After a few zaps, I did start taping them up..Live and learn.

[nnn0rau]

Thanks!

Ordered the #1 cable & the Tweco sets yesterday evening (WelderDepot & Ram Supply)... I never thought of the anti sieze - GREAT IDEA!!!

[Sberry]

Yes, they use steel setscrews and they are darn near ruined if they seize in, nice to be able to get them out to tighten connectors or change them around down the road.