Extending welder leads

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I have a Miller thunderbolt stick welder and want to extend the leads, the factory leads are size #1, can I add say 50 ft of 1/0 to each or stay with the #1 ? ThanksMiller 252 Mig w/Spool GunMiller Dynasty 350 TigMiller 225 AC-DC StickMiller Spectrum 875 PlasmaOxy/Acet.
Reply:Depends on what kind of amperage you will be running. I would say you'll be fine with #1 lead as long as your not running to many amps through it. Ie; air arcing as that takes High amperage and you run the risk of melting your leads or quick connects.1973 Lincoln SA 200, Already replaced shunt coils, Idle board (SOLD)1984 Miller Dialarc 250HF, Miller water cooler, 250 AMP water cooled torch, you know the worx.
Reply:I had a older thunderbolt that used the red plastic pin type push in connector with #1 cable. I bought two sets of Jackson connectors so I could use the 1/0.   I cut the miller cable about one foot long and installed the jackson connector to it and the other end to the 1/0.  I bought about 100' of 1/0  with jackson connectors on it in 20' and 25' lengths. Now I had choice of short or longer cables and didn't have to have all that cable stretched out  if not needed.  I used the cut off #1  for stinger end as a light weight whip.
Reply:i used tweco cons. #1 will be fine. Attached Images225NT bobcatAEAD200LEScott 125mm175, mm252 w 30A, PT225mm211, TA 181iHyper Therm 380, cut master 529100X & XX, Digital Elite6 Victor setssmith little torch, meco midget kalamazoo band sawsteel max saw evoulution circular saw
Reply:Originally Posted by TuscanyDepends on what kind of amperage you will be running. I would say you'll be fine with #1 lead as long as your not running to many amps through it. Ie; air arcing as that takes High amperage and you run the risk of melting your leads or quick connects.
Reply:I have a Miller Thunderbolt that my dad ordered stock from Miller with 50ft leads on it. It's a pain in the ***. I need to pick up some reasonably sized leads (15ft) for it... just doesn't seem to be too happy running the longer leads at all.Miller Performance AD Helmet - Camo Edition Soon to have: Jackson HSL 100 - Forest Digi CamoMiller Thunderbolt AC/DC((Currently at welding school))
Reply:Hey Lights... like jbmprods showed in his welder photo, you could use some tweco connectors and section up your 50-foot leads... maybe into 15 ft and (50-15) = 35 ft leads. Having no leads connected to the welder is great.If you want short leads, then you connect your 15 leads with electrode holds and ground clamp.If you want long leads, add in your 35 ft sections.Rick V 1 Airco Heliwelder 3A/DDR3 CTC 70/90 amp Stick/Tig Inverters in Parallel1 Lincoln MIG PAK 151 Oxy-Acet
Reply:Originally Posted by BD1I had a older thunderbolt that used the red plastic pin type push in connector with #1 cable. I bought two sets of Jackson connectors so I could use the 1/0.   I cut the miller cable about one foot long and installed the jackson connector to it and the other end to the 1/0.  I bought about 100' of 1/0  with jackson connectors on it in 20' and 25' lengths. Now I had choice of short or longer cables and didn't have to have all that cable stretched out  if not needed.  I used the cut off #1  for stinger end as a light weight whip.