Welding Leads

Keeping the welding leads in good shape on your portable arc welding is a constant concern. Poor leads makes for a poor welding experience. Before we got to work today, we took time to repair the leads on our Lincoln SA 200. 

The ground cable has been hit the hardest, for whatever reason. These leads are old, but good. When we first got this welder over 10 years ago, we worked over the leads. Now it's time to do it again. 

Here's an example of a spot we fixed back then. Still holding strong. 

What happens is that the insulation breaks on them. If left unattended, they can ground out and melt the copper, which is what is happening here. I think it is all still salvageable. 

First, disconnect the ground cable from the ground clamp. 

Heat-shrink is our product of choice. Black tape is just not durable enough for the abuse these guys take around the ranch. These sticks of heat-shrink we've had sitting around for years. Work great for a job like this. 

Just cut a section, longer than the need. 

Slip it onto the cable. 

And over the break.

Then get to heating. I find a heat-gun to work the best. In time, it just melts down to the cable and sucks up, tight. 

Should work. We had about three of these breaks to fix, today. 

The best thing for lead care, is keeping them coiled up good and orderly. 

Back to work.

Good deal. This has been needing to be done for quite a while. If you don't tend to these breaks, you are going to compromise your leads, at best. They can also ground-out on other metal, shock you, or just make welding experience frustrating. Better deal with the insulation breaks as they happen. An ounce of prevention is worth a pound of cure! Ranch on.