Weight extension Lifehack for a welder

When purchasing a welding machine, many of us notice that the length of the welding cores leaves much to be desired. And if the welder works stationary (in one place), then short wires do not interfere with the work process ... But if you have to constantly change your place of work, then ... dragging a welding machine with you somehow does not bring pleasure.

It is better, of course, to replace the core of the holder. But! You will have to “repack” the core from the side of the contact connector and from the side of the holder. Or ... buy a longer core with a holder and a connector.

If I had made such a decision, then this article could have ended.

So… How did I do it?

I did not do any manipulations with the core of the holder for a banal reason: the welding machine is still under warranty and if you suddenly have to take it in for warranty repairs, the native cores should be in order.

Therefore, I decided to increase the length of the "mass" core. Besides... I don't need a long vein every time. As a result, I made ... a kind of extension cord. Now I will explain its advantages, disadvantages and design.

Advantages:

- Near the place of work, there may not be a good ground connection point (for example, everything is painted, it is undesirable to clean it).

- You can change the place of work without reconnecting the mass (of course, within the length of the mass core extension cord)

- Using a clamp instead of a clamp ensures good contact with the product.

- When a long strand of mass is not needed, it can simply be turned off.

Flaws:

- The presence of an open non-insulated connection of the (native) clamp with an extension cord. This is contrary to PB. However, since we are “collective farms”, this place can be protected with a plastic bottle with a cut off bottom.

— Theoretically, a slight drop in the welding current is possible. In fact, I didn't notice.

I made this extension cord, as they say ... "from what was at hand"

The cable is used brand PVS 3x6. The veins are paralleled. Total - section 18 mm2. In continuous mode, the allowable current is about 110-120A.

A copper (Used / Ear) tip is installed on one of the ends of the extension cord. The native clamp of the “ground” core will be connected to this point.

The second end, it was decided to equip with a homemade clamp with a bolt welded to it

The clamp is made of 50mm wide steel bar. The thickness of the steel is 5 mm.

The end of the hairpin (M10), sharpened under the cone.

I planned to weld another “cone” on the inner platform of the clamp opposite the cone of the stud - for better contact. But... and so everything works well. I abandoned this idea.

This is what the extension cord looks like.

Contact is always good. If necessary, you can quickly reconnect.