Replacing connectors on welding cables

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I bought an older Sears AC stick welder. The model number starts with 113. The insulation on the cables is cracked in many places. I bought some new cable and I want to re-use the connectors. Do any of you know how to remove the old cable and instal the new?


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Reply:You could cut the cable about an inch or so before the connector and use a crimp barrel on the bare wire of each piece, heat shrink tube, plastic tube or cood electrical tape or liquid tape. I also have an old Craftsman 230 amp machine & that's how I added to my cables. You could also add DINSE connectors on to the old plugs, they come with an insulator sleeve that would eliminate the need to insulate stuff, I'd go with DINSE 50, OR if you want a good proper job you can put panel mount connectors and connectors for the leads. Here's a link for them on AMAZON.https://www.amazon.com/dp/B07MZ7LLB6...mcd_asin_0_imgNRA LIFE MEMBERUNITWELD 175 AMP 3 IN1 DCMIDSTATES 300 AMP AC MACHINELET'S GO BRANDON!"Those who would give up essential Liberty, to purchase a little temporary Safety, deserve neither Liberty nor Safety.” BENJAMIN FRANKLIN
Reply:@CavemanDude! You have a great idea with panel mount connectors! I was feeling gloomy because I found something more serious than rotted insulation.

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Reply:Easy repair for the board  , drill the rivits out of the brackets , get a piece of 1/8 or 1/4  in.  thick garolite , use the old one for a pattern . Do you have any friends that are industrial electricians ?  They could get you a small piece of garolite , without having to buy a large sheet of it .Last edited by yooper; 1 Day Ago at 07:19 PM.
Reply:@yooper: Thanks for the suggestion. I *am* a variety of industrial electrician! Mostly pipe and wire guy. I didn’t know what that board was called. Never dealt with it. I *was* thinking of a repair like you suggest but I like panel mount because the old male connectors seem to have welded themselves and damaged their threads pretty badly.

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Reply:Ok I have a question that has probably been asked before but I am not sure how to search for it. I apologize for repeating.

So I can figure out that one cable plugs in the top row and one in the bottom row. I see that there 12 power settings possible by different choices. My question is: does it matter which cable  goes top and which bottom?  Also if I install panel mount connectors which would be red and which black?Sent from my iPhone using Tapatalk
Reply:I'm a little surprised you even had connectors... my old blue Sears unit is hard wired right into the front of the cabinet and like you, the cables are overdue for a change. I will also be using the Dinse connectors on the front so I can be a cheapskate and just buy short cables but still be able to steal the long cables off my Dialarc if need be . It's an AC machine so polarity isn't an issue like a DC machine, but I would make the ground/work outlet the red one, and the stinger side the black one for continuity if I do swap leads between machines.

The harder you fall, the higher you bounce...250 amp Miller DialArc AC/DC StickF-225 amp Forney AC Stick230 amp Sears AC StickLincoln 180C MIGVictor Medalist 350 O/ACut 50 PlasmaLes
Reply:

Originally Posted by Eric H-L

Ok I have a question that has probably been asked before but I am not sure how to search for it. I apologize for repeating.

So I can figure out that one cable plugs in the top row and one in the bottom row. I see that there 12 power settings possible by different choices. My question is: does it matter which cable  goes top and which bottom?  Also if I install panel mount connectors which would be red and which black?Sent from my iPhone using Tapatalk
Reply:It's a ac welder so it makes no difference which cable { electrode or ground } goes to top or bottom .
Reply:Just replace the old bolts with new brass nuts and bolts and wing nuts  - any good   " industrial electrician "  should have access to them