Welding lead capacity

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I'm looking to buy some welding lead reels and new leads for my truck, I can't get a straight answer to the ampacity of the welding leads at different lengths, I want to have 150ft leads total, 75ft on each reel, I rarely even weld with 1/8 rod, but I want to be able to, I also run a spool gun off the truck too, not sure what the amps are when I'm running that.Will #1 welding wire work for that?I could go 1/0 but I'm trying to save on costEvery different chart I see has a different number seems like when it comes to Max length for fifteenth lead sizesThanksSent from my SM-G973U using Tapatalk

http://www.philswelding.com
Reply:

Originally Posted by MetalMan23

I'm looking to buy some welding lead reels and new leads for my truck, I can't get a straight answer to the ampacity of the welding leads at different lengths, I want to have 150ft leads total, 75ft on each reel, I rarely even weld with 1/8 rod, but I want to be able to, I also run a spool gun off the truck too, not sure what the amps are when I'm running that.Will #1 welding wire work for that?I could go 1/0 but I'm trying to save on costEvery different chart I see has a different number seems like when it comes to Max length for fifteenth lead sizesThanksSent from my SM-G973U using Tapatalk
Reply:That is true, I didn't think about the dual shield, .045 or 1/16, I don't want to have to buy all new leads if I want to add that capability in the futureSent from my SM-G973U using Tapatalk

http://www.philswelding.com
Reply:

Originally Posted by MetalMan23

I'm looking to buy some welding lead reels and new leads for my truck, I can't get a straight answer to the ampacity of the welding leads at different lengths, I want to have 150ft leads total, 75ft on each reel, I rarely even weld with 1/8 rod, but I want to be able to, I also run a spool gun off the truck too, not sure what the amps are when I'm running that.Will #1 welding wire work for that?I could go 1/0 but I'm trying to save on costEvery different chart I see has a different number seems like when it comes to Max length for fifteenth lead sizesThanksSent from my SM-G973U using Tapatalk
Reply:Lincoln Ranger 225 Sent from my SM-G973U using Tapatalk

http://www.philswelding.com
Reply:Here's what Miller recommends:

Miller Multimatic 255
Reply:You do know the cost is over $1,000.00 for each cord.Dave

Originally Posted by MetalMan23

I'm looking to buy some welding lead reels and new leads for my truck, I can't get a straight answer to the ampacity of the welding leads at different lengths, I want to have 150ft leads total, 75ft on each reel, I rarely even weld with 1/8 rod, but I want to be able to, I also run a spool gun off the truck too, not sure what the amps are when I'm running that.Will #1 welding wire work for that?I could go 1/0 but I'm trying to save on costEvery different chart I see has a different number seems like when it comes to Max length for fifteenth lead sizesThanksSent from my SM-G973U using Tapatalk
Reply:

Originally Posted by smithdoor

You do know the cost is over $1,000.00 for each cord.Dave
Reply:

Originally Posted by MetalMan23

Lincoln Ranger 225 Sent from my SM-G973U using Tapatalk
Reply:This is out of the manual for my 330mpx.

Lincoln 330MPXLincoln Power Mig 256Lincoln LN-25X Wire FeederMagnum PRO 250LX GT Spool GunLincoln AC/DC 225¼ Ton of Torches OFC-A OFG-AAir Carbon Arc Gouging CAC-AEverlast 62i Plasma CutterIngersoll Rand T-30 14hpInstagram: #Freebird Welds
Reply:I have the same length cables as what you are wanting, I plan on stick only with a max of 1/8" so I went cheap and got #2 leads. Same kind of work you're doing. If it was in the budget I would have gone 1/0 just for the occasional air-arc job. I used the same charts the guys posted above. I know already that I'm not going top be working it anywhere near capacity or duty cycle.Use a bigger hammer.
Reply:I was talking about cord winded up reel .But cord is not cheap too.Dave

Originally Posted by Freebirdwelds

here are some decent prices on flex-a-prene.https://www.harrisweldingsupplies.co...e-cut-lengths/
Reply:

Originally Posted by smithdoor

I was talking about cord winded up reel .But cord is not cheap too.Dave
Reply:Maybe a backpack gasoline welder would be cheaper.  Would a good workout too. Dave

Originally Posted by Freebirdwelds

Gotcha.


Reply:

Originally Posted by smithdoor

I was talking about cord winded up reel .But cord is not cheap too.Dave
Reply:Looks great 👍. This type I am use too. But your is a lot better https://www.mcmaster.com/7353K416/FYI  I only purchased for Doors upto 150 foot long. Never would buy one for my work Dave

Originally Posted by MetalMan23

https://store.cyberweld.com/diamond-...%2BKh*e-RGFqwSThat's what I'm looking atSent from my SM-G973U using Tapatalk
Reply:

Originally Posted by MetalMan23

https://store.cyberweld.com/diamond-...%2BKh*e-RGFqwSThat's what I'm looking atSent from my SM-G973U using Tapatalk
Reply:Little tip. You can get the cable they use for welding leads at electrical supply stores that have cable.Gear: Esab power compact 205 with tbi industries torch         BOC Smootharc 185dc tig         Miller Syncrowave 350LX
Reply:These are realatively short and just cause a guy hooks wire,,, (especially spool gun) to it doesnt mean its going balls out.  I like 1, so much easier to handle and you got to be hanging off the edge to over work it.  If you are concerned about needing heavier,,, you wont.   If you know you need heavier now then its different.  You can air arc with it,,, just cant do huge steady.   Your machine will be a smoldering cinder before you overwork 1.www.urkafarms.com
Reply:

Originally Posted by William Payne

You can get the cable they use for welding leads at electrical supply stores that have cable.
Reply:I buy all of my new lead from www.electronbeam.comTheir lead is top quality, and always the best prices."Where's Stick man????????" - 7A749"SHHHHHH!! I sent him over to snag that MIC-4 while tbone wasn't looking!

" - duaneb55"I have bought a few of Tbone's things unlike Stick-Man who helps himself" - TozziWelding"Stick-man"
Reply:

Originally Posted by Louie1961

Here's what Miller recommends:


Reply:I agreeIt is very good chart .Dave

Originally Posted by Cobraone

Louie, that clears things up nicely!
Reply:Miller has a lot of great charts and things like that that are really helpful. They even have a neat slide rule you can buy where you set what type and thickness of material you want to weld and what type of join and it gives you a rough idea on what your setup should be depending on what process you are doing.Gear: Esab power compact 205 with tbi industries torch         BOC Smootharc 185dc tig         Miller Syncrowave 350LX
Reply:You have a good sense of practicality and came to a good conclusion.   Don't let that good sense be shaken by obsessive types.  I might be inclined to put 85 or 90 ft on the stinger. Something else with modest lead and simple setup.  I getva connector and a ground clamp and hook to the machine. For the stinger a connector and a electrode holder to start with.  You can always add more before coming up with a scheme involving a couple of every connector they invented.   Maybe lugs on machi e and males on leads but that stuff really grows and adds to cost.  This was a revision,,,,  removed all this from one circuit, just kind of grew over the years.

Originally Posted by Stick-man

I buy all of my new lead from www.electronbeam.comTheir lead is top quality, and always the best prices.
Reply:

Originally Posted by Oscar

I noticed that Electron Beam cable has a thicker jacket than flex-a-prene, and the strands aren't as fine, which actually makes it look like a larger gauge.  The 1/0 EB looks like 2/0 flex-a-prene when side by side.  Anyhow, just an observation.  I bet their 4/0 looks even more massive.
Reply:Thick cable is cool and all. And electron is good cable (not knocking it all I've bought it before) but their 2/0 weighs 108lbs per 200'. Flexaprene 2/0 weighs 86lbs per 200' ( pos and neg cable). When your hauling 400' of just 2/0 cable add connectors, clamps, stingers, etc.. Then factor in bulk. Space and weight is a premium when your mobile. Not counting #2 cable or whips. I'm in my 60's now and humping this is enough.

Lincoln 330MPXLincoln Power Mig 256Lincoln LN-25X Wire FeederMagnum PRO 250LX GT Spool GunLincoln AC/DC 225¼ Ton of Torches OFC-A OFG-AAir Carbon Arc Gouging CAC-AEverlast 62i Plasma CutterIngersoll Rand T-30 14hpInstagram: #Freebird Welds
Reply:

Originally Posted by Freebirdwelds

Thick cable is cool and all. And electron is good cable (not knocking it all I've bought it before) but their 2/0 weighs 108lbs per 200'. Flexaprene 2/0 weighs 86lbs per 200' ( pos and neg cable). When your hauling 400' of just 2/0 cable add connectors, clamps, stingers, etc.. Then factor in bulk. Space and weight is a premium when your mobile. Not counting #2 cable or whips. I'm in my 60's now and humping this is enough.


Reply:

Originally Posted by 52 Ford

Just get an inverter stick welder, put shoulder straps on it, and wear it like a backpack. THEN all you need is a couple feet for the leads and a LONG extension cord.Sent from my Lincoln Buzzbox using Tapatalk
Reply:The best welding cable is the really fine wire stuff that is often used for the stinger cable only because it is also the most expensive. Having said that the finer the strands the more flexible it is. You sure wouldn't want to use 2/0 building cable. Flex-A Prene and equivalents of other brands have pretty good flexibility and are a good compromise on flexibility and weight. If the EB cable was more than twice as heavy although less expensive, it would be factor for when you need to haul or drag long cables. I bought used cable from Red-D-Arc several years ago, $2/ft. for 2/0 cable with quick connects on each end. It was in good shape and almost half the price of new cable without the quick connects. Back in the mid 80's I bought used 2/0 cable for them and it was only $1/ft. In hindsight I should have bought 100's of feet of it and just held on to it for 20+ years and made a good profit. Might have been a very good investment as the price of copper has skyrocketed.