Miller Trailblazer 250G short problem

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Help!! I was doing some cleaning on my Trailblazer 250G and noticed some soot on the inside of the cover and when I looked at the machine, much to my dismay, I discovered the cause: apparently the insulation has been rubbing on the cover, and one of the wires shorted out, and burned through. Obviously I will have to either fix this myself, or have this repaired. Has anyone ever had this happen on their machine? Can I splice in a new piece of wire? Can it be soldered? Or should a mechanical splice (such as using a split bolt) be used? Also what can I use to re-insulate the wire? You can see on the right hand side of the picture, that that wire insulation is also wearing through from rubbing on the cover.



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Reply:If it were mine I'd clean off any insulation coating and use a mechanical crimp splice using the existing piece of lead.  I'd "patch" the damaged insulation with a piece of heatshrink tube and wrap the entire bundle with plastic wire loom.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110

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Reply:

Originally Posted by duaneb55

If it were mine I'd clean off any insulation coating and use a mechanical crimp splice using the existing piece of lead.  I'd "patch" the damaged insulation with a piece of heatshrink tube and wrap the entire bundle with plastic wire loom.
Reply:

Originally Posted by ironwrx

Thanks for the input. I thought about using heat-shrink, but wondered  if the wires would possibly heat up in use, and if the tubing could handle the temperature? I mean, why would the original insulation be fiberglass not plastic? Also what about high voltage rubber tape?Sent from my iPhone using Tapatalk
Reply:This possibly, don't see it in red.High-Temperature Electrical-Insulating Tube Sleevinghttps://www.mcmaster.com/standard-ca...tube-sleeving/

or   https://www.newark.com/c/cable-wire-...leeving-tubingLast edited by albrightree; 04-04-2021 at 12:48 PM.Airco 250 ac/dc Heliwelder Square waveMiller Synchrowave 180 sdMiller Econo Twin HFLincoln 210 MPDayton 225 ac/dcVictor torchesSnap-On YA-212Lotos Cut60D
Reply:

Originally Posted by albrightree

This possibly, don't see it in red.High-Temperature Electrical-Insulating Tube Sleevinghttps://www.mcmaster.com/standard-ca...tube-sleeving/


Reply:

Originally Posted by ironwrx

That looks perfect for insulation, but how shall I reconnect the wires? I think crimp sleeves are mainly for stranded, not for solid wire. Sent from my iPhone using Tapatalk
Reply:

Originally Posted by SweetMK

Get it big enough to slide over the crimped on end,,,
Reply:I suppose it depends on how good of a crimper you have.
Reply:

Originally Posted by walker

I suppose it depends on how good of a crimper you have.