Best way to splice/connect welding leads???

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Just wondering if anyone else has any other tactics to splice welding cable. I have always used Tweco and Lenco cable connectors, and they seem to work fine. But, I don't like paying for them.  Tell me whatcha got..........Proverbs 4:23My company welds.
Reply:Same as you. I tried my way first and found my cheap idea was just that. lolSent from my iPhone using Tapatalk
Reply:if you are doing high-profile work, I don't suggest going outside the realm of normal connectors, but if it is for you and maybe a few other's to see and you don't mind using tools to remove splice. . . .heck cable-clamps and elect tape?bosses stuff:trailblazer 325maxstar 200my stuff:sa 200fronius transpocket 180100 amp Lincoln w/f97 f350 DITKevin
Reply:I just use large Tweco's, but I have seen repairs using a large crimped-on connector, covered with thick heat-shrink tubing.  They didn't look like a Bubba repair job, but somebody here more familiar with the regs could probably let you know the OSHA / whatever legality on that type of repair.
Reply:Tweco makes a set screw splice. Just a tube with set screws to hold the cables and a sleeve to cover it up. Two ring lugs and a bolt taped up are used a lot. If it has to be real clean, there are the tweco and dinze style connectors. It all depends if you have to keep a safety guy happy, what you can use and get away with. Any type of splice can get very hot if not done right.So watch where you put them and check them for heating.
Reply:They all are costly. I have Jacksons.
Reply:It's my shop. I'm the safety guy. lol Originally Posted by ccawgcTweco makes a set screw splice. Just a tube with set screws to hold the cables and a sleeve to cover it up. Two ring lugs and a bolt taped up are used a lot. If it has to be real clean, there are the tweco and dinze style connectors. It all depends if you have to keep a safety guy happy, what you can use and get away with. Any type of splice can get very hot if not done right.So watch where you put them and check them for heating.
Reply:osha actually strictly forbids repairing the insulation on welding leads of you go by the book.     Take that for what its worthLast edited by Dualie; 01-09-2014 at 12:27 AM.Vantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.
Reply:the twist lock types are best imvho but have gone the plumbing copper tube route in a pinch.i.u.o.e. # 15queens, ny and sunny fla
Reply:Originally Posted by docwelderthe twist lock types are best imvho but have gone the plumbing copper tube route in a pinch.
Reply:Originally Posted by pigeonpoopFor home shop use only, I'd try this:I've got one of them nifty Harbor Freight hydraulic crimper kits.....I use it to make welding leads and custom battery cables...But always with heavy terminal lugs designed for crimping.Consider using a heavy duty butt splice designed for crimping, and then wrap with quality rubberized electrical tape finished off with two layers of shrink wrap.Here is an example...larger sizes availablehttp://www.maneywire.com/butt-connec...-196-l-en.html
Reply:Originally Posted by stovepipe699I like pigeonpoops idea if you don't want to use connectors.  I'm setting my cable up with connectors.  I got some weldmark(lenco clone), some lenco, and some tweco.  They are all interchangeable lc40 and 2mpc, but I prefer the tweco.  They turn a lot further to lock and I beleive will stay connected better.  I'm keeping the tweco and returning the other stuff.  My 2 cents for anyone interested
Reply:Yes. Well, they ain't got me yet.  Originally Posted by Dualieosha actually strictly forbids repairing the insulation on welding leads of you go by the book.     Take that for what its worth
Reply:I use Anderson type connectors a 350 amp one for my Idealarc and a 175 for my AC225. I can't say they are better than anything else but they do work very well and with the work I do I have tons of good used connectors and 1/0 & 2/0 extensions laying around.  I have the Anderson(work clamp is always negative on the connector for my setup) coming off the machine from there I can use extensions or attach the stinger and work clamp pig tail. I had the same setup on my Bobcat that I just sold that worked really well also. Last edited by kald; 01-09-2014 at 10:20 PM.Idealarc 250AC 225SVictor OA-older made in USA stuff.And a crap ton of other stuff.
Reply:Originally Posted by 7A749Man, that looks good kald.Did you change the paint up on it??As far as a super cheap way to splice cable, get some large Burndy crimp connectors for splicing, drill some 5/16" or so holes in them, one on each end, join the stripped ends of the cable into it & sliver braze them up inside the holes until the braze sweats into the entire connector.I use wet rags wrapped on the rubber insulation to prevent it from burning while I'm brazing it. Wrap it up with electrical tape & good to go.