New leads for Miller Thunderbolt 225/150 AC/DC

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Ok so I have the newer T-bolt that the leads go directly in the machine and I want to upgrade/lengthen the leads on it. I consulted the Miller charts and I am planning on using #2 leads with the goal to buy it in 25ft sets and use quick connects to add or subtract as needed per project. I don't plan on getting more than 100 ft total cable length. I have seen where a lot of people have just cut the existing #4 lead off about 1ft from the machine and then added quick connects there. Is there an issue leaving this small section of #4 still going into the machine or should I make the #2 also which means I need to get some lugs for the wire and then figure out a way to install a strain relief/insulator bushing on the front of the machine since I assume the old one would not work. I considered putting a Dinse panel mount on the front like the older machines but not quite sure if that is necessary or not. Also I have considered going up to #1 leads just in case in the future I need some extra distance from my leads. So I guess I need advice on which setup would be better 1st with regards to cable size and then with leaving the old #4 leading into the machine or replacing it all the way inside to the lug connections. Dinse panel mounts or just quick connects hanging outside the machine. Also I plan on using the existing #4 leads as whips on the front of whichever new leads I get unless you all advise against that. Thanks in advance to all!
Reply:You have two ways to go...But fersure replace the sections of #4 at the machine...If you had short sections of #4 at the work ends of they leads it wouldn't be a problem, but not at machine end.One popular way is to install connector that fit into the front machine sheet metal, then cable to inside with short lugged jumpers...The other way is to just run the new leads thru sheet metal like factory setup and install twist connectors about a foot away from machine like you already described.All you will need to it either way is of course the leads, and the CORRECT terminal lugs, and whichever cable connects you like.One of handiest tools I ever bought from Harbor Freight is their hand held hydraulic crimper.  I use it very often to make new battery cable, welding leads, used to take it to work often to use there, and of course loan to friends.Make certain to get heavy walled lugs designed for crimping at the round collar, not the cheap thin walled stuff if you desire a no resistance connection.But friend, beware that 100 foot leads on that little machine  is asking for trouble no matter how large the wire leads....Especially with connectors every 25 foot....In effect, you will be welding with 200 foot of lead and 8 connectors...That is LOTS of resistance for low voltage like used in welding when you trying to circulate lots of amps...Big machines do it all day long, but I've owned the exact machine made by Hobart and wouldn't expect it to do it well even at 50 foot.Last edited by wornoutoldwelder; 03-07-2016 at 10:34 AM.