Welder Repairs and general project questions.

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Hey everyone, im after some repair advice on my welder and some general information on a project i was considering Firstly ive been given a welder from a friend of mine (PowerLine Arc welder 130amp). now im not dumb enough to just plug it in and go, been as i know nothing about the thing. so i decided to give it a visual inspection inside and out to make sure there was no obvious signs of problems etc.so far everything has turned up find and it looks fine to use, however the one problem i have noticed is that the earthing cable for the welder (the one with the clamp on). has quite a serious cut in the cable, its not damaged the copper inside but the plastic covering is knackered around it and was taped up. should i leave this as it is or go the route of replacing the cable? the only reason i ask is that it was taped up well to ensure it was kept dry and safe, my only concern about replacing the cable is that its not screwed or bolted onto the transformers ground wire but its crimped on using what looks like a metal ring compressing the two wires together. i would have no clues really on how to safely replace this the only other reason i would want to replace it is due to the length of the ground wire which is about 2 foot at max.any good suggestions or advice would be good.onto my second question:ive decided that as a first project with the welder (if it ever works), i would like to have a crack at making a small gate for my front entrance (insert ur jokes here hehe), nothing special, its only going to be about 3 foot by 3 foot in size, my only question is that i have no clue on what welding rods i need to get, what metal, amperage to set the welder etc... the questions go on and on lol.thanks for any advice you can offer.krisI don't care what the question is. The answer is More Power!
Reply:post some pics of the machine including the internals if you canDynasty 200DXPassport plus w/ spoolmate 100victor 315c oxy/(act and prop)Miller digital elitemilwaukee power tools
Reply:If the earth cable damage hasnt broken too many of the conductors in the cable then it should be fine as is.I have replaced an earth cable before, I found it hard to get a proper butt cable splicer like you mentioned, so I got a lug type connector designed to terminate a cable to a bolt and it was big enough to get both cables in, so I crimped it on and cut the loop off with a grinder and tie wrapped the thing back so it wouldnt short.You can jury rig a crimp tool out of a vice and something pointy.
Reply:ok as requested heres some pic of the welder, internal and external bits and pieces, the black wire shown is the one in question it looks quite bad but as mentioned the copper core is still intact, although slightly corroded.any advice would be appreciated, the rust on the transformer seems to be nothing more than surface as a good bit of wirewool could remove it.KrisI don't care what the question is. The answer is More Power!
Reply:bumpy I don't care what the question is. The answer is More Power!
Reply:You can fix that frayed ground cable with some 3M electrical tape (I prefer friction tape) and then coat it with 3M ScotchkoteCo-Own CNC shop:Miller :1251 plasma cutter, MaxStar 700 TIG/Stick, & XMT 456 Multiprocess Welder.&  2 Hypertherm HPR260's Plasma CutterSorry I had a bad stroke but now I am back.
Reply:First i would determine if the welder works properly or near properly, than replace any cables, switches, hardware. You will need someone that can weld to help you evaluate the unit. Maybe add a cooling fan.
Reply:It looks like that ground (earth) cable should be replaced.  It looks like you will have to uncrimp that tube, obtain a replacement tube (or sleeve with screws) and replace the wire right where the crimp is today.Safety first.. and on that note, a couple of questions?  Do you have access to 240v 20amps (preferrably 30 Amp) circuit?  Current carrying capacity is dependent on the wire size of your supply.. here in the USA 12 gauge wiring is coded for 20 amps maximum.   And no you can't just change the circuit breaker / fuse up.  (that's how fires get started..)  Do you have access to a 240volt clothes dryer outlet?  I'm a little bit ahead of you, but still a newby working on my arc welding skills.  I did take a semester class on welding at the local community college, but one thing I did that really helped me was a video that we saw in class.  I went ahead and purchased the video on my own.  The video is Arc Welding 1 from http://www.weldingvideos.com/  The narrator really tells you how to read the arc in the video.  I think I've watched that video six or seven times, and I'm still learning from it.Recommended rod for your A/C arc welder?  I'd go with 3/32" E6011, 3/32" E6013 and possibly some 3/32" E7018 AC.   I'd also recommend obtaining access to a 4.5" grinder.  Building a project is a great way to learn.. When you build a project, you discover its 90% prep/post work and only 10% welding.  I think you would use the 6011 rod for practice and tacking up your project, then use the 6013 for the rest of your gate welds.  Also, for my first project, I planned on filing the welds smooth... and I think the 6013 is MUCH easier to grind/ file than is the 7018.Good luck!--zipLast edited by zipzit; 03-03-2010 at 12:57 AM.
Reply:Originally Posted by zipzitIt looks like that ground (earth) cable should be replaced.  It looks like you will have to uncrimp that tube, obtain a replacement tube (or sleeve with screws) and replace the wire right where the crimp is today.Safety first.. and on that note, a couple of questions?  Do you have access to 240v 20amps (preferrably 30 Amp) circuit?  Current carrying capacity is dependent on the wire size of your supply.. here in the USA 12 gauge wiring is coded for 20 amps maximum.   And no you can't just change the circuit breaker / fuse up.  (that's how fires get started..)  Do you have access to a 240volt clothes dryer outlet?  I'm a little bit ahead of you, but still a newby working on my arc welding skills.  I did take a semester class on welding at the local community college, but one thing I did that really helped me was a video that we saw in class.  I went ahead and purchased the video on my own.  The video is Arc Welding 1 from http://www.weldingvideos.com/  The narrator really tells you how to read the arc in the video.  I think I've watched that video six or seven times, and I'm still learning from it.Recommended rod for your A/C arc welder?  I'd go with 3/32" E6011, 3/32" E6013 and possibly some 3/32" E7018 AC.   I'd also recommend obtaining access to a 4.5" grinder.  Building a project is a great way to learn.. When you build a project, you discover its 90% prep/post work and only 10% welding.  I think you would use the 6011 rod for practice and tacking up your project, then use the 6013 for the rest of your gate welds.  Also, for my first project, I planned on filing the welds smooth... and I think the 6013 is MUCH easier to grind/ file than is the 7018.Good luck!--zip