gun lead length

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I am wondering just what opinions are on length.  Over the years I am noticing that people love long gun leads.  Yesterday I encountered a 16 footer.  The person using it was complaining about the welding machine having problems.  It was a wire feed problem but the machine was blamed. ( .045 flux core)   For some reason there are two camps of opinion.  One says the longer the lead the better since you have to reach in sometimes.    I am noticing all the situations where someone wants a longer lead is where they really should be "dragging" their feeder closer or hanging it on a hook.  Of course all the people/shops who seem to have problems with their machines are ones with long leads.  Any thoughts?  Any opinions?  Best compromise length?
Reply:I say get the whip just long enough. When I run off a suitcase welder I like a 10 foot whip. A lot of cats like the 12 and 15 foot whips but I find I get a lot of binding issues and wire feed issues with the longer whips. But I also have noticed that when I ahve a short 6 foot whipe I get some of the same issues. I think its all a matter of making sure that the lead is free of any sharp bends. To long and there are tons of curves for the wire to feed around...to short and there can be some sharp bends when you have to really reach for something.'Mike
Reply:I run 15' and 12' and 10' mig guns and dont normally have feed problems on the longer ones any more than the shorter ones.  The key with the long ones is to make sure you're running the right size liner for the wire size.  Running .035 wire in an .045 liner doesn't work all that well when the length is long.   The wire tends to 'snake' inside the liner cause of the loose fit and feed erraticaly.   Use the correct liner/wire size and the wire pushes down the torch nice and smooth like it's supposed to.   The one-size-fits-all liners that come with most machines are really not the best choice for smaller wires.The other key is don't let the excess cable length coil and tangle up on itself when welding close to the machine.  Lay it out in a big arc if possible and it will feed smoother.   Another consideration is if the gun liner easily floats and rotates in the gun cable or if it is held tight.  If it can float and rotate easily the coils of the liner stay tight and don't open up.  If it binds, it can be damaged and cause a kink for the wire to have to pass through.  The kink can't be seen untill the liner is removed.Last edited by DesertRider33; 10-06-2009 at 11:30 AM.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:Thanks for input.  Another fly in the ointment is one wire when measure is not .045 or 1.2 mm  It is in fact 1.3 mm  Some guys have resorted to using .052 contact tips.  Add multiple machines and multiple wires, and two gun brands to the mix and I am scratching my head.
Reply:I used to go round and round about this very topic with my father. He was ALWAYS buying 6' whips and saying how they fed so much better than the longer whips. we had to stop letting him order the new guns. Its a ROYAL P.I.T.A. to be bound by a short MiG whip.ALL of my LN-25's that are set up to run FCAW have 12'+ whips. In fact i even think all of my mig's have 12'+ to 15'+ whips.Vantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.
Reply:I use a 15' and as long as I rememeber to watch out for sharp bends like DesertRider33 said I have no problem. I hate short leads, you constantly have to be hauling the machine around....Mike