Soldering leads on their connectors or just set screw?

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Ok this should be an easy one. Any special wire prep needed for connecting a Dinse connector on the cable? (for work clamp and lead). I've come across conflicting advice. Can I just use the set screw or is there a "right" way to do it? I've seen many folks soldering their crimps but being a set screw, wondering if that's it" Wam, bam, done?My apologies for the onslaught of questions... but until now, I've been able to walk into my tech schools metal shop, grab a booth with a fully loaded Dyn 350 and start welding... I'm currently putting together a DC tig setup at home.  Getting close!  I appreciate every reply and many thanks to those who have taken the time to share their experience and knowledge.- Kenneth
Reply:Soldering will always have a better conduction because you are ensuring more surface area contacting, almost all of it if you solder correctly by heating the wire and not just melting the solder and dropping it on.From a welding standpoint I can't really comment, but I can't imagine a set screw makes a huge difference.
Reply:Holy **** are you serious? Set screw and be done. What are you trying to Frankenstein together anyway?Torchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:Originally Posted by BrooklynBravestSoldering will always have a better conduction because you are ensuring more surface area contacting, almost all of it if you solder correctly by heating the wire and not just melting the solder and dropping it on.From a welding standpoint I can't really comment, but I can't imagine a set screw makes a huge difference.
Reply:If its got a set screw I say its all you need. That way you can replace or up grade the cord quickly and easily later on if needed.Wrap a strip of copper sheet around the wire before inserting into the holder.Some of the terminal lug connectors inside my machine and the battery cable lugs on my diesel crimped and soldered, mainly just to keep dirt or water from getting up inside the connections. Did this on both fine stranded welding cable and common course stranded THHN wire.Last edited by mad welder 4; 09-19-2014 at 12:58 AM.old Miller spectrum 625 Lincoln SP-135 T, CO2+0.025 wireMiller model 250 and WP-18V torchCraftsman 100amp AC/DC and WP-17V torchCentury 115-004 HF arc stabilizerHome made 4 transformer spot welderHome made alternator welder
Reply:Originally Posted by walkerThat would be great advice except for the fact that it is dead wrong when it comes to welding cables. The connectors that have the ball screw just screw them in and be done. If you have to fix any with lugs, DO NOT solder them! It creates a high resistance joint that gets hot. They become progressively worse as you use them. I did all mine when I was starting out. They came out perfect, heat shrinked the ends, etc. i have had problems with each one of those ends, and have had to redo them all. I just bought a cable crimper and crimped the new lugs on and no problems, for years since.
Reply:I like to wrap the loose strands of wire with brass shim stock then clamp down with the set screw.  Years ago cable ends came with a brass or copper warp with the ends.  Another member here threw out the idea of cuttng a piec of copper tubing in half and putting that between the wire and the set screw.  I just like to keep the cable strands in a tight pack for more contact area.Dan D.Manipulator Of Metal
Reply:No one I've ever met is careful enough to not flex them at the end. Over time you will cut the cable back, and renew the connection. I do like the big sealant filled heat shrink I buy at Home Depot. They give some support against the fraying at the joint. Use Noalox, and set screw.
Reply:No soldering.    If you have some soft copper tubing slice a small piece and use it at set screw location. The old days manufacture supplied a thin copper sheet cut to size to  form around strands .
Reply:This is the proper way to do it, according to the manufacturer:http://dinse.eu/wp-content/uploads/d...-GB%2010Nm.pdfIt's important to have the right size welding cable depending on the connector. Worst scenario is to take a cable that is too thin for the connector and just screw it down without any sleeve around the wires. Then there is only a small number of strands that are carrying all the current. As you use the cable these small wires break of one by one. In the end it's all 'bout having a good electrical connection betwean the wires and the connector.Last edited by Pete.S.; 09-19-2014 at 10:27 AM.