Welder Cables

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Just picked up these 2 machines today. The Powr Kraft 180 AC has some pretty long 3 AWG aluminum cables on it, the Lincoln AC/DC 225 has the stock short, copper cables-- but they are smaller gauge.  I am keeping the 225 and selling the 180. Would swapping the longer aluminum wires to the 225 AC/DC be a bad idea? I know the alum doesn't conduct as well. Seems like it would be a 'wash' to me as the alum. cables are larger?I will mostly be doing very small welding jobs like making jigs and tools and fixing stuff, very intermittently.Thanks in advance!
Reply:They are definitely Aluminum?Not just plated copper?Seems odd but I suppose its possible...IMO, I wouldn't change them, if anything, I would go longer Copper.
Reply:i bought a miller 333 amp 3ph miller that came out of hewlitt packards maintnance dept.  it had big fat alum leads.    i never used them, but know someone who has.   i think you'll be fine w/ them.     i know a surplus dealer who bought a bunch of leftovers from the oil pipleine in alaska.   literally pickup loads of 1/4 concave grinding wheels, and big 1/8,  etc.   he said there were alum leads that came from that buy, and he sold them to guys, who mostly built cow corrals, and they were happy w/ them.   it always suprised me about alum in alaska, i wasn't there, and didn't see them, but i don't know why the old man would lie.   anyway, being the 225 barely runs 1/8 7018 hot enough, i'm guessing the only gripe you might ever have, is that you see a lil drop in your heat if your streching out there.   your only doing light stuff, i'm thinking you'd/ I'd  never know the difference.
Reply:I cant see aluminum wire being flexible enough to be used as welding cable..Ive seen many breaks in aluminum wire when its used in service lines.Above and underground.I would pull the aluminum cables off the 180 and scrap them.24 feet of #4 cable will make the 180 run better.It is limited 37.5 amps primary draw so it could run on rural lines.Leave the AC/DC Lincoln as it is.The POWER KRAFT name is a Montgomery Ward trade mark.I have been using a Lincoln 225S since 1964. The cables a large enough
Reply:That Power-Kraft 180 is quite unusual, almost every Wards/Sears welder I have seen is made by Century. First time I've ever seen a re-branded Lincoln tombstone.As far as the cables are concerned, they will be fine. 3 ga. aluminum is equivalent to 4 ga. copper and quite adequate for a 180A welder. Leave them on the 180 and sell it as-is.If the cables on the AC/DC Lincoln are too short, put Tweco connectors on them and extend them with 2 ga. welding cable, which is plenty for up to 50' lengths on that machine.JohnA few weldersA lot of hammersA whole lot of C-clamps
Reply:Thanks for the input guys. All of the cables are are going to stay on the current machines.
Reply:Originally Posted by Silicon-basedThat Power-Kraft 180 is quite unusual, almost every Wards/Sears welder I have seen is made by Century. First time I've ever seen a re-branded Lincoln tombstone.As far as the cables are concerned, they will be fine. 3 ga. aluminum is equivalent to 4 ga. copper and quite adequate for a 180A welder. Leave them on the 180 and sell it as-is.If the cables on the AC/DC Lincoln are too short, put Tweco connectors on them and extend them with 2 ga. welding cable, which is plenty for up to 50' lengths on that machine.John
Reply:I think they stopped making the 180 version by the mid-'60's.  The widely spaced side-by-side leads were changed around 1969.They sold new for about $85. Emerson Electric made a lot of the older Sears welders."USMCPOP" First-born son: KIA  Iraq 1/26/05Syncrowave 250 w/ Coolmate 3Dialarc 250, Idealarc 250SP-175 +Firepower TIG 160S (gave the TA 161 STL to the son)Lincwelder AC180C (1952)Victor & Smith O/A torchesMiller spot welder