HOW TO - make a 220V extension cord
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  1. #1
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    HOW TO - make a 220V extension cord

    After so many redundant questions and posts, I figured I would make myself a cord for my TIG, in turn, making a "how to" for this section.

    I hope this is correct, any electrical gurus please chime in.

    The purchase: Home Depot 10/3 50ft. extension cord, NEMA 6-50P plug, NEMA 6-50R receptacle.
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    Preparing the cord, strip off the 110V connectors, strip the wrap:
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    Green is ground, black and white are power. The plug comes with very good directions, just follow those. It also comes with either a 30A prong or a 50A prong (installed by default).
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    The 50A plug is all done, screw the cover back on, as well as, the cable crimp and you're done:
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    Receptacle in next post...
    Last edited by MicroZone; 05-22-2007 at 11:42 AM.
    John
    - fabricator extraordinaire, car nut!
    - bleeding Miller blue!

    http://www.weldfabzone.com


  2. #2
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    Re: HOW TO - make a 220V extension cord

    The receptacle end is the same - green is ground, black and white are power. I made sure to connect like colors on the "big tooth" or the larger pin. I am lacking words this morning, still first cup of coffee.

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    The aftermath, cut 110V connectors, various cable encasing:

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    Testing the cable on the MILLER plasma, Test is SUCCESSFUL :

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    That's it, fairly simple. Any questions, just ask. Yes, I will be putting a box around the receptacle end.
    John
    - fabricator extraordinaire, car nut!
    - bleeding Miller blue!

    http://www.weldfabzone.com


  3. #3
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    Re: HOW TO - make a 220V extension cord

    Quote Originally Posted by MicroZone
    ...The purchase: Home Depot 10/3 50ft. extension cord, NEMA 6-50P plug, NEMA 6-50P receptacle...
    MINOR correction: On the devices, "P" signifies "plug," "R" is "receptacle," and "C" is "connector." A "connector" is the female receptacle that is designed for direct installation to the end of an extension cord, as opposed to one that is designed for a box or wall-mount.

  4. #4
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    Re: HOW TO - make a 220V extension cord

    Thanks for the correction MAC, I knew my terminology was off only after 1 cup of coffee.
    John
    - fabricator extraordinaire, car nut!
    - bleeding Miller blue!

    http://www.weldfabzone.com


  5. #5
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    Re: HOW TO - make a 220V extension cord

    Why the yellow tape on the ground? I might actually recommend against that. It is common to see a yellow stripe down the length of a green ground, but a fat yellow band around it could actually be seen as a recoloring. Of course, you're not likely to screw it up in this application, but I thought I'd point that out.

    Also, you really should recolor the white wire, since it is now a hot and no longer a neutral. This is most easily done with a marker, just making it a second black (or any color other than white, gray, or green), along its entire visible length.

    While there is nothing wrong with making the same hot wire on the same size pin, I'll just point out that it is not required.

  6. #6
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    Re: HOW TO - make a 220V extension cord

    Good catch - I cut a slit in the ground wire and wanted to be extra safe to keep the ground wire from arcing or other on the power wire. Dang - I have green tape too...but it's a cable just for me so I threw the first available e-tape on there I could grab.

    A VERY good idea MAC! If the cable were to be sold, I would color it black...VERY important.

    Got it - so I really didn't have to be anal retentive and put the same color wire on the matching big pin. Must be my OCD late last night - finished it up at 2 a.m.

    Thanks again for the pointers and additions to the picture tutorial. I hope it at least lessens the load to the amount of new posts regarding " how do I make an extension cord for my Clarke, Lincoln, or Miller 220V welder ".

    edit: correction on x,y,z per MAC 3 phase reference.
    Last edited by MicroZone; 05-22-2007 at 11:56 AM.
    John
    - fabricator extraordinaire, car nut!
    - bleeding Miller blue!

    http://www.weldfabzone.com


  7. #7
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    Re: HOW TO - make a 220V extension cord

    Oh great, "X, Y, Z" means 3-phase! Now you've done it...

  8. #8
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    Re: HOW TO - make a 220V extension cord

    Hahahaa...I mean ESAB, HTP, Lincoln, Miller or Thermadyne!
    John
    - fabricator extraordinaire, car nut!
    - bleeding Miller blue!

    http://www.weldfabzone.com


  9. #9
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    Re: HOW TO - make a 220V extension cord

    Quote Originally Posted by MicroZone
    Good catch - I cut a slit in the ground wire and wanted to be extra safe to keep the ground wire from arcing or other on the power wire. Dang - I have green tape too...but it's a cable just for me so I threw the first available e-tape on there I could grab.

    A VERY good idea MAC! If the cable were to be sold, I would color it black...VERY important.

    Got it - so I really didn't have to be anal retentive and put the same color wire on the matching big pin. Must be my OCD late last night - finished it up at 2 a.m.

    Thanks again for the pointers and additions to the picture tutorial. I hope it at least lessens the load to the amount of new posts regarding " how do I make an extension cord for my Clarke, Lincoln, or Miller 220V welder ".

    edit: correction on x,y,z per MAC 3 phase reference.
    just curious,how much$ was the plug and cord.
    LINCOLN IDEALARC 250
    LINCOLN AC/DC 225/125
    FRANKENSTEIN HOBART 300 AMP AC
    MILLERMATIC 130
    LINCOLN PRO MIG 175
    CENTURY 110V STICK
    SMITH TORCH SETUP

  10. #10
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    Re: HOW TO - make a 220V extension cord

    The Leviton brand plugs and receptacles of this type are usually 8-14 dollars at Home Depot. They also have the all-in-one receptacle in a plastic box which will mount on a wall or on the end of a cord.

  11. #11
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    Re: HOW TO - make a 220V extension cord

    Quote Originally Posted by MAC702
    The Leviton brand plugs and receptacles of this type are usually 8-14 dollars at Home Depot. They also have the all-in-one receptacle in a plastic box which will mount on a wall or on the end of a cord.
    Thanks mac ,I have to buy a couple,right now i only have one and have keep switching it from welder to welder,kind of tired of it.
    LINCOLN IDEALARC 250
    LINCOLN AC/DC 225/125
    FRANKENSTEIN HOBART 300 AMP AC
    MILLERMATIC 130
    LINCOLN PRO MIG 175
    CENTURY 110V STICK
    SMITH TORCH SETUP

  12. #12
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    Re: HOW TO - make a 220V extension cord

    It came to $82 with Tax...not bad.
    John
    - fabricator extraordinaire, car nut!
    - bleeding Miller blue!

    http://www.weldfabzone.com


  13. #13
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    Re: HOW TO - make a 220V extension cord

    Hey MAC just wondering if this was ok, if it is i'll post pics, but i split one hot and the common neutral and wired them to a 110v recepticle. So now on me extension i have a large box with one 220v and one 110v recepticle. That way i can run an angle grinder or some other tool without having to run another extension cord.
    I do make sure not the run the welder and the acessory at the same time. My dad showed me how to do this on one of his extension cords so i did it to mine, just not sure its up to "CODE".

  14. #14
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    Re: HOW TO - make a 220V extension cord

    Mac ,i have another question for you,its probably a pretty stupid question but i just wanted to make sure.I have a 220v extension cord,I want to fit the plug end with with the dryer type plug with the L prong on it,but I want fit the receptacle end with the common type setup,so say i purchase a machine with the factory type plug ,it will work so i wont have keep fitting machines with the dryer plug.will this setup work.
    LINCOLN IDEALARC 250
    LINCOLN AC/DC 225/125
    FRANKENSTEIN HOBART 300 AMP AC
    MILLERMATIC 130
    LINCOLN PRO MIG 175
    CENTURY 110V STICK
    SMITH TORCH SETUP

  15. #15
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    Re: HOW TO - make a 220V extension cord

    Quote Originally Posted by fordtrucks
    Hey MAC just wondering if this was ok, if it is i'll post pics, but i split one hot and the common neutral and wired them to a 110v recepticle. So now on me extension i have a large box with one 220v and one 110v recepticle. That way i can run an angle grinder or some other tool without having to run another extension cord.
    I do make sure not the run the welder and the acessory at the same time. My dad showed me how to do this on one of his extension cords so i did it to mine, just not sure its up to "CODE".
    It's not to Code, like you suspect.

    Now, ask me if I made one, too...

  16. #16
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    Re: HOW TO - make a 220V extension cord

    Quote Originally Posted by chrysler tech
    Mac ,i have another question for you,its probably a pretty stupid question but i just wanted to make sure.I have a 220v extension cord,I want to fit the plug end with with the dryer type plug with the L prong on it,but I want fit the receptacle end with the common type setup,so say i purchase a machine with the factory type plug ,it will work so i wont have keep fitting machines with the dryer plug.will this setup work.
    Very common issue.

    Do you currently have a 3-prong dryer receptacle, or a 4-prong?

  17. #17
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    Re: HOW TO - make a 220V extension cord

    Quote Originally Posted by MAC702
    Very common issue.

    Do you currently have a 3-prong dryer receptacle, or a 4-prong?
    3 prong with that L prong
    LINCOLN IDEALARC 250
    LINCOLN AC/DC 225/125
    FRANKENSTEIN HOBART 300 AMP AC
    MILLERMATIC 130
    LINCOLN PRO MIG 175
    CENTURY 110V STICK
    SMITH TORCH SETUP

  18. #18
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    Re: HOW TO - make a 220V extension cord

    Quote Originally Posted by chrysler tech
    3 prong with that L prong
    You need a NEMA 10-30P plug on one end and a NEMA 6-50R receptacle on the other (for standard welding machine plugs.)

  19. #19
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    Re: HOW TO - make a 220V extension cord

    Quote Originally Posted by MAC702
    You need a NEMA 10-30P plug on one end and a NEMA 6-50R receptacle on the other (for standard welding machine plugs.)

    thanks
    LINCOLN IDEALARC 250
    LINCOLN AC/DC 225/125
    FRANKENSTEIN HOBART 300 AMP AC
    MILLERMATIC 130
    LINCOLN PRO MIG 175
    CENTURY 110V STICK
    SMITH TORCH SETUP

  20. #20
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    Re: HOW TO - make a 220V extension cord

    I thought about doing this too...but then I do alot of work for electricians and didn't want them to think I cob stuff up. It's a great idea but I like to keep things neat and tidy.

    Quote Originally Posted by MAC702
    It's not to Code, like you suspect.

    Now, ask me if I made one, too...
    John
    - fabricator extraordinaire, car nut!
    - bleeding Miller blue!

    http://www.weldfabzone.com


  21. #21
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    Re: HOW TO - make a 220V extension cord

    It's funny you mention that because I see cobbed stuff all the time, and my first thought is, well, that's what I'd do, but I wonder if this guy did it safely or just out of ignorance....

  22. #22
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    Re: HOW TO - make a 220V extension cord

    My sentiments exactly MAC, I'd rather not have someone say, "hmm, I wonder if he cobbed that or did he really make a neat device?". Up here, we call it "rigging" and it's often the blunt of many jokes.
    John
    - fabricator extraordinaire, car nut!
    - bleeding Miller blue!

    http://www.weldfabzone.com


  23. #23
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    Talking Re: HOW TO - make a 220V extension cord

    Ok no pics then. No need to start something that will eventually get out of had.
    But if its good enough for MAC and Micro its good enough for me.
    Thanks guys you eassed my mind

  24. #24
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    Re: HOW TO - make a 220V extension cord

    Just a follow up - I was out in the big shop and had my TIG connected via this extension cord and was TIG'ing at MAX amps for about 3 hours. The cord held up fine, provided great power and never even got warm. I was checking it from time to time to double check my work...dang OCD.
    John
    - fabricator extraordinaire, car nut!
    - bleeding Miller blue!

    http://www.weldfabzone.com


  25. #25

    Re: HOW TO - make a 220V extension cord

    Sorry first post,

    I just got me a Linclon 225/125 AC/DC arc welder and I need a 50' extension cord to run from my dryer to the welder. The dryer plug is three prong with the L shaped ground. Will 10/3 cord be fine or will it not have enough poop to do it or start on fire. Just want to make sure I don't waste my money on getting a cord thats not good enough.

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