How can to butt-weld flexible steel wire?

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Greetings,I'm interested in making a loop of steel wire that is about 6 feet in circumference.  I'm not yet sure about the diameter of the wire, but it needs to be flexible so it can run around some pulleys of maybe 1 inch in diameter or less.  While under tension, it will experience a force of no more than about 10 pounds.  Long ago, I put together bandsaw blades using the electrical welder that was built into the bandsaw, so I'm assuming that thin steel can be butt welded and still remain somewhat strong and flexible if treated properly.  So I have a few questions: First, what sort of steel would be good for this kind of application?  What should I buy? How would it have to be welded, using what sort of equipment?And I presume it would need to be heat treated somehow (annealed?) after the weld???Any suggestions will be much appreciated,thanks,Mark
Reply:The only 'wire' that can withstand a constant wrapping/unwrapping around a pulley that small will be a small diameter braided-of-very-fine-wire cable. The best way to make an endless loop would be to unravel each end and re-braid it back together, as is done with rope and occasionally, heavy cable. Trying to weld or solder the cable as a whole will cause  a lump, and stress points on each side of the junction so it will break fairly soon, even with the annealing. Trying to braze or weld each wire individually will be nearly impossible, and would still require the same unraveling/re-braiding in order to space the individual joints.
Reply:Oldiron is right.Only thing I've seen was on a past thread about 2 months ago where a guy talked about welding cable used on ski lifts.  It's extremely specialized, and not something for us hackers, well this hacker anyhow(me)"Any day above ground is a good day"http://www.farmersamm.com/
Reply:Would you be able to use similar size copper wire and solder it together?I did this to make a very light and strong loop to drag deer out of the woods with.  5 deer later the solder is still holding.Have we all gone mad?
Reply:Originally Posted by sn0border88Would you be able to use similar size copper wire and solder it together?...
Reply:I think I just used 10-12 ga automotive wire I got at autozone or something, 50/50 solder maybe.  Ive wrapped up the wire around the handle when its not in use and its never kinked or anything if thats what your worried about.My solder had a little buldge to it, but I dont see why you wouldnt be able to make it smooth, or wrap it up in heat shrink to help.Have we all gone mad?
Reply:Originally Posted by sn0border88I think I just used 10-12 ga automotive wire I got at autozone or something, 50/50 solder maybe.  Ive wrapped up the wire around the handle when its not in use and its never kinked or anything if thats what your worried about....
Reply:I'm wondering what type of application this is going to be used for?Miller Thunderbolt 225Millermatic 130 XPLincoln HD 100 Forney C-5bt Arc welderPlasma Cutter Gianteach Cut40ACent Machinery Bandsaw Cent Machinery 16Speed Drill PressChicago Electric 130amp tig/90 ArcHobart 190 Mig spoolgun ready
Reply:Originally Posted by STwelderI'm wondering what type of application this is going to be used for?
Reply:If you used a ring traveling between multiple pairs of rubber pulleys pressing on the ring,  both as guides and/or drives, it could be solid, not need flexing, and easier to make. Any other reason this would not work?
Reply:I am sure you could find an o-ring that might fit the bill.http://www.quickcutgasket.com/o-rings.htmlLast edited by 59halfstep; 04-23-2009 at 12:09 PM.Charlie
Reply:Originally Posted by Oldiron2If you used a ring traveling between multiple pairs of rubber pulleys pressing on the ring,  both as guides and/or drives, it could be solid, not need flexing, and easier to make. Any other reason this would not work?
Reply:O-rings can be cut and bonded. How about surgical rubber tubing?Of course you'd have to check chemical compatibility, but a 25" OTR tire o-ring is probably close to 6' in circumference.Attachment 32121Good LuckLast edited by denrep; 10-19-2010 at 11:36 PM.
Reply:Is the fluid too sticky to pump through a loop of tubing and just tap off a bit where you need it? a loop would allow you pump at a faster flow rate,  and allow you to tap off a small quantity with minimal delay. would sound a LOT easierfred
Reply:Originally Posted by denrep...Of course you'd have to check chemical compatibility, but a 25" OTR tire o-ring is probably close to 6' in circumference.Attachment 32121Good Luck