February 1, 200719 yr A fellow ask me to replace the weldings leads on an old working buzz box. What is your suggestion to making the plug in lead longer and how long? Can you gain anything by making this cord longer to save the cost of the welding leads? What is your suggestions for a good working length for the ground and stinger leads?
February 1, 200719 yr Each persons requirements or needs are different, generally speaking the lead with the rod holder should be about 10 foot longer than the ground lead, as the ground is just clamped on to the work and the rod holder lead has to be capable of moving around the work in different locatons.
February 1, 200719 yr Glenn when I was welding for a living we had quick disconnects we had leads from 20' to 100' long. It was like a pigtail at the machine was very nice. I would go to your local weld shop they could set you up.
February 1, 200719 yr I also use the pigtails. I have a set of relatively short leads for work in the shop and a set of longer leads I keep on the wall for work out in the white rock & cocoa wheats. Works well for me, Like Jr says the ground is about 10' shorter on the short leads and I have it about 20' shorter on the long leads. JWB
February 1, 200719 yr Do you need to go bigger gauge ??? I know runing saws the longer the cord the harder it is on the tool.
February 2, 200719 yr Ron, your gonna lose some electricity due to resistance of the wire. The longer the wire, the more you lose. As far as I know, the gauge is really only relative to size of amps you are trying to move. The bigger the gauge the safer the higher amperages..
February 2, 200719 yr I have a 20' long "extension cord" for my buzzbox and it helps a lot. You don't need to upsize the wire as much since the amp draw is less on the high voltage side of the box. Currently I have to run it into the house to the kitchen stove outlet to ues the welder. Waiting on the electrician to get power to the shop... Thomas
February 5, 200719 yr I have always used a 20' stinger lead that's made from a discarded TIG lead and have never had ANY problems. Granted, that was when I was welding in the boilers for a living, but we used to string leads 100 -200 feet from machine to worksite and had very few problems. The only REAL problem was when someone would unplug you and steal your lead!! GRRRRRR!!
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