Switching out the ground cable.......

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09-09-2011, 01:41 AM
Steve

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Switching out the ground cable.......

Ok...I have the Weltec 25 foot 20 series flexible torch. Really nice.

But.....I was still stuck with being 10 feet from the Powertig 250EX because of the grounding cable. And the pedal cable is 15 feet so that will have to be changed out too!

So I decided to switch out the ground cable. Went to Tractor Supply and they have 1/0 welding cable so I bought 25 feet of that along with a new cable eye end.

I figured out that you have to pry the factory dinse cover away by heating it up with a hand held hair dryer and gently pry the rubber cover off the dinse connection. It will slide down the cable when it is free.

You then will have to remove the cable from the male metal end of the dinse with the allen head screw. The cable will just pull out.

You will notice that there is a ferrule wrapped around the cable as it is doubled over to make for a really good connection. It has a split in it and can easily be bent away from the cable. Pull the cable out and then unbolt the other end of the cable to the ground clamp.

Then take the new cable, strip off about 1 inch of the insulation from the end. Add the eye connector and bend over the cable for the dinse end. Make sure you put the cover over the cable before you put the ferrule and dinse on. Tighten the allen head over the inserted ferrule/cable. Then slide the rubber dinse cover back over the brass end and you are done.

It is really easy and allows for the re-use of the factory dinse ground connector. It's really nice to be able to move around the shop without having to worry about being stopped by the ground cable. Next project is a new SSC foot control pedal and longer 25 foot cable.
09-09-2011, 02:32 AM
performance

I've never needed a hair dryer, only a vise. After you slip it back a time or two it pops off fairly easily...It IS meant to be serviced. A tight grip and back and forth twising motion will loosen it up so it slips back.
09-09-2011, 04:03 AM
Steve

Quote:

Originally Posted by performance

I've never needed a hair dryer, only a vise. After you slip it back a time or two it pops off fairly easily...It IS meant to be serviced. A tight grip and back and forth twising motion will loosen it up so it slips back.

The hair dryer softens up the cover and makes it a whole lot easier to pop off. I've used the hair dryer trick to put small diameter gas lines into the little bit larger barbs on the quick connect gas fitting. Of course if you have no hair and have no need for a hair dryer....then your way works too!
09-09-2011, 01:58 PM
performance

I am amazed that when people find out the lengths of the cables and are wanting more, they say "Oh no!! that's to short" and they start to fret and doubt the purchase. Had a guy this week was worried about it and wanted to buy a machine that was 200.00 more and a whole lot less amps just to get longer cables. I told him that 20 bucks would fix the problem. Same thing with the electrode holders and work clamps. Always get a call with someone wanting the other style or saying it wasn't as nice as what they wanted. I tell them 12.00 will fix that.
09-09-2011, 06:04 PM
Steve

Quote:

Originally Posted by performance

I am amazed that when people find out the lengths of the cables and are wanting more, they say "Oh no!! that's to short" and they start to fret and doubt the purchase. Had a guy this week was worried about it and wanted to buy a machine that was 200.00 more and a whole lot less amps just to get longer cables. I told him that 20 bucks would fix the problem. Same thing with the electrode holders and work clamps. Always get a call with someone wanting the other style or saying it wasn't as nice as what they wanted. I tell them 12.00 will fix that.

Even though a customer is always right, sometimes it makes you wonder!

In the business my family was in, we told a few first time customers that we did not want their business because we knew right away they would be trouble as long as they were around. We wrote them off. Sometimes, it is best to just walk away from some customers that will be trouble.

Modifying stuff is part of the fun! I liked messing around and putting a new smaller torch on my Everlast Powertig 250EX. It was kind of fun looking for the parts, getting them and installing them. Same with the ground. I installed a new brass 400 amp clamp along with the 25 foot cable. It was fun doing it and a learning experience. I now know a little more about my Everlast by doing the mods. Just like getting a car and modifying it to fit what I want it to do.

I do know what you mean though. It can be frustrating at times.
09-20-2011, 04:02 PM
Jules The Great

Mark,

You guys could offer extension cables with the correct fittings on each end, or have you guys already looked into the cost of doing this?
10-08-2011, 11:29 PM
DVA

How long is the Everlast Tig torches provided with their tig welders?
10-08-2011, 11:43 PM
zoama

Quote:

Originally Posted by DVA

How long is the Everlast Tig torches provided with their tig welders?

About fifteen feet.
10-09-2011, 01:52 AM
SeanMurphy265

I think has something to do with experience and being around the welding industry. No machine comes with decent length leads or decent ground clamp. I was part of setting up a structural steel shop several years ago. We fab tubes (columns) for Wal-Mart at the time. We bought 8 Lincoln power sources (all 440) to run .52 wire (flux core). Two of the machines were used as stick machines to tack. None of the machines came with leads, clamps, or stingers.

Welding machine companies tend to stay away from selling cable. Hobart has a market with the chain store, and lincoln has a 100' or 50' package they used as a deal this summer if you purchased certain generator welders. With the copper market being so crazy I can't blame them.

Sometimes you can find deals for leads from Amazon at a good price.
10-09-2011, 11:39 PM
acourtjester

Here this may help some with longer ground cables.
http://www.everlastgenerators.com/fo...r-ground-cable
Dropped the price to $20. plus shipping
You can use a short section of copper tube to slip over the bare cable end so the allen screw clamp holds better.

havr fun
Tom
10-10-2011, 01:47 PM
hooda

I won't have the funding available for two weeks, but count me in for 2 of these. Prefer 1 red, and 1 black but if not available, any color will do.

Quote:

Originally Posted by acourtjester

Here this may help some with longer ground cables.
http://www.everlastgenerators.com/fo...r-ground-cable
Dropped the price to $20. plus shipping
You can use a short section of copper tube to slip over the bare cable end so the allen screw clamp holds better.

havr fun
Tom