Converting air reel into a welding reel

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Well I finally got a chance to work on my reels for my welding leads today. As stated before in my Ultimate mixer thread I had planned for this for a while but other projects got in the way.   The hardest part of this was building a cheap and easy swivel for the power. I didn't want to run the power through the reel itself since there would be a danger of ruining the spring. I got sticker shock looking at prices of copper bars so decided to use a slightly modified version of what one of my friends did one time. I used the large size cam lock quick connects for the base unit. First things first is to modify them so that they can spin all the way around. The first one I did like my friend did by grinding the lug out of the hole. This works but when I got done I realized there wouldn't be anything to keep it in place. The second one I ground the groove deeper and widened it toward the end so that it could turn easily. I also beveled the edges at the factory break in the end so that if it slipped out slightly it would pull itself back in. Unfortunately I forgot to take pics of this part.  Next was the problem of them turning to stiff for the spring rewind. There's also not enough spring in the center split to keep it tight IMHO. I decided to split the outside part so that I could control the tension on the pin. To keep tension I thought about a spring type hose clamp but unfortunately I didn't have one the right size. So I made my own from a old coil spring. I can add more or change later if it proves to not be enough but I think it'll be fine like it is.   Next was the need to mount the revolving part to the reel. I wanted it insulated as stated before and it needed to revolve with the reel. I decided to mount it with the original cable clamping hole on a pin sticking out so on with the search for insulating material. I didn't have any 5/8" air brake line but I did find some plastic bushings that where a little large. I used the bandsaw to cut a slit and then the 1" wide belt sander to sand the slit till they just pressed in the hole. I then measured the hole and found it just a little under 1/2". To save time I just grabbed some bolts and sanded the threads till they fit (it was faster than setting up on the lathe and turning some stock). I then used my handy plastic stock to make a disc for the bottom of the hole.  Now how to get the welding cable connected. The original clamp set screw is 9/16". I've not got any fine threaded bolts that size. Thus I decided to drill and tap on the opposite side for a 3/8" NF bolt. This also left more meat for the cable end to make contact with.   I then made the mount for the swivel. The easiest way seemed to be just use a piece of 1/8" x 1" strap and weld the bolt to it. I lubed them with dry moly first and worked that in. Then I used anti seize for a lube to keep them from galling.   I insulated the stinger reel at the base when I mounted it to the bracket just in case it ever gets shorted to the cable for some reason. I used 1/16" thick nylon sheet and 1/2" OD hard nylon tubing to do the insulating.   As you can see I still need to install the lead to the welder. I will have to make a arm to screw to the side of the still part of the swivel to keep it from twisting the lead when I do. But the humidity is so high today that I decided I needed to dry out instead of finish it. Attached ImagesMillermatic 252XMT 304'sDynasty 280DXHypertherm PowerMax 1250Miller Trailblazer 302 EFIOptima PulserXR feeder and XR Edge gun and more athttp://members.dslextreme.com/users/waynecook/index.htm
Reply:Irish that is a sweet set-up no doubt.  In addition to the work and stinger reels are those air and mixed gas from your mixer board?  That is a sweet deal if you got it hooked up that way.  Are you planning to use a quick connects on the machines and just switch your gas mix at the board and plug it in as appropriate?  Anything to keep the floor uncluttered and it looks like you hit a homer on that!!!!!I'm spending my Kids inheritance, I dont like him that much anyway!!!!!!Enuff tools to do the job, enough sense to use em.Anybody got a spare set of kidneys?  Trade?
Reply:That is a great design.  Any thoughts about selling the swivel assemblies?  I would be interested in a few of them.  I hate how my wires are on my cart and laying around the garage.  Dont have a lathe to make any of these but sure would love to get the wires under control.Please PM me if you are interested in selling some of the couplers.Thanks, Scott
Reply:Originally Posted by RbeckettIrish that is a sweet set-up no doubt.  In addition to the work and stinger reels are those air and mixed gas from your mixer board?  That is a sweet deal if you got it hooked up that way.  Are you planning to use a quick connects on the machines and just switch your gas mix at the board and plug it in as appropriate?  Anything to keep the floor uncluttered and it looks like you hit a homer on that!!!!!
Reply:Irish Fixit,I always enjoy seeing creative inventions and solutions.Nice job!
Reply:Outstanding, have you tested the brass couples yet to see if they heat up? I suppose the only issue would be how fast they wear.Matt
Reply:Originally Posted by joedirt1966Irish Fixit,I always enjoy seeing creative inventions and solutions.Nice job!
Reply:Since there seems to be a lot of interest in lead reels I thought I would add some pics of my old reels that I just replaced. These worked great for years but they have to be down low where you can crank them by hand. I wanted the spring rewind so that I could mount them up high out of my way. Thus the reason for the switch.   These where pretty simple to build. I just used the rear spindles from a front wheel drive car and a couple of old wheels. The one on the left I added the tabs so it could handle more cable. The black rings are all scraps of Nylatron (moly impregnated nylon) that I had laying around (I have a lot of these left over from doing pump jack bearings like the ones in the Lot of brass thread). I insulated the spindle from the bracket by drilling and tapping into one of those nylatron rings and bolting the spindle to it. I then drilled and tapped holes 45deg out from the first and bolted it to the mount. I just used the spindle bearings as the swivel on these and never had any problems with them. The ring on the lever is the brake. It provides the friction surface and insulation at the same time. There are more than one spring setting to allow for adjustment. I also used one of the rings for the cable guides on the front. Attached ImagesMillermatic 252XMT 304'sDynasty 280DXHypertherm PowerMax 1250Miller Trailblazer 302 EFIOptima PulserXR feeder and XR Edge gun and more athttp://members.dslextreme.com/users/waynecook/index.htm
Reply:Well I finished the installation today and ran 5 sticks of 3/16" 7018 at 225 amps to test it. The swivels barely warmed any if at all. You can see how I went about bracing the swivel to keep it from wrapping up the cable. I do like to try and keep the KISS principle in mind when designing things as long it doesn't hinder usefulness that is. :-) Attached ImagesMillermatic 252XMT 304'sDynasty 280DXHypertherm PowerMax 1250Miller Trailblazer 302 EFIOptima PulserXR feeder and XR Edge gun and more athttp://members.dslextreme.com/users/waynecook/index.htm
Reply:here is a set of reels that i have made barrowed the idea from another guy just need some lexan for insulation  so your stinger and ground don't arc across that way your stiner is hot all the time works great on rigs Attached ImagesLincoln Pro Core 125Lincolin sp 100Miller Big 40Lincoln Idealarc SP250miller matic 212http://www.facebook.com/hdwelding?sk=wallwww.hdweldingbeds.com
Reply:That's a good looking set. A lot of work goes into a set like that.Millermatic 252XMT 304'sDynasty 280DXHypertherm PowerMax 1250Miller Trailblazer 302 EFIOptima PulserXR feeder and XR Edge gun and more athttp://members.dslextreme.com/users/waynecook/index.htm