how to measure welding lead size? (diameter)

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all the charts i see list the physical size of the welding leads in nominal o.d.  if i want to determine the size of a set of leads that i have, do i measure the diameter of the conductor(just the copper)  or the whoel cable (copper and insulation) to get the nominal o.d.?  i would like to use the physical size in order to determine the size lead that i have.  they came with a machine that i bought and are in very good shape, they just don't have any markings of any sor on them.  thanks.
Reply:You measure the conductor not the insulation."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:thats what i thought.  i assumed that the insulation would vary according to manufacturer.  i'll measure the copper tomorrow to see what size leads i have.  thanks.
Reply:ran into a problem with my leads.  when i measure my leads, the physical size of the copper is 7/16".  .4375.  every wire table i could find is showing #2.  but, i tried a #2 and even a #1 lug (hobart brand from TSC) and they did not fit.  the measurements say #2 but i need a 1/0 lug to make it work.  there are no size markings on the lead.  any ideas on what size lead i have?   does it have to be 1/0 because that is what size lug will fit or is it #2 based on the measurement?  thanks
Reply:According to carol cable, 0.475 is the outer diameter for their #2 lead. Be sure you are comparing apples to apples. Check again and let us know."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:.4375 is the outer diameter of just the copper.  that measurement does not include the insulation.  i have never measured the leads including the insulation.  obviouslay it would be considerably bigger, but i thought that to determine the size of the lead i needed to measure just the copper conductor.
Reply:just went out and looked a little closer.  after knocking all the crud off of the out side of the leads, i noticed it is in fact #2.  apparently hobarts measurements are a little off.    if i was to buy some more lead, will upgradign to #1 or 1/0 benefit me if i were to keep the #2 leads in the welding circuit or am i limited by my #2 leads regardless of the size of teh new leads.  i have 50' of work and 50' of electrode.  200 amps will be the absolute extreme