Another wire rope question

[Woodskevin]

Hello again. I have a lot of 1/2 wire rope. I'm guessing it will twist, compact, and weld at approximately 1/4 inch rods. Has anyone of you or someone you know taken 4 or 5 of this size wire rope and twisted them up to make a larger diameter for a pattern welding project?

[Francis Trez Cole]

Yes I did and I have made 5 and 7 piece welds on the 7 I did not pre twist and weld just welded the ends and twisted it as a bundle. worked just fine

[fciron]

Same here, seven pieces of smaller wire rope make a tidy bundle. I welded mine while twisting it in a v-block. Once I had the cable welded I forged it into rectangular bar and stacked those without any further twisting.

I find it's actually easier to weld larger cross sections. They are less likely to burn up and they stay at welding temp longer.

[Woodskevin]

Thanks. You mind if I ask what wire you used to hold the bundle?

[Jason @ MacTalis Ironworks]

I personally use either crapload of 14ga bailing wire, or some 18ga stainless. I twist it up every 2 wraps or so. Though I prefer to just tack weld with either OA or TiG, as it holds better.

[781]

you can also weld up the 1/2 wire rope into a round then twist some left hand and some right hand then square them and weld them side by side alternating so you get a herring bone pattern
Leave them round to twist then square
I use a bottom swage to do the initial weld into round