Soft copper tube for butt splice
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  1. #1
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    May 2010
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    Soft copper tube for butt splice

    Anyone ever used soft copper tube for butt splicing
    welding cables?
    One of my cables has a big tape covered knob where
    I spliced it with a split bolt.
    Looking for something smaller than a set screw type
    connector.
    Soft copper tubing,crimped with a hammer type
    swage tool, and covered with heat shrink?
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  2. #2
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    May 2014
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    Central Wa. state
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    Re: Soft copper tube for butt splice

    Quote Originally Posted by jpump5 View Post
    Anyone ever used soft copper tube for butt splicing
    welding cables?
    One of my cables has a big tape covered knob where
    I spliced it with a split bolt.
    Looking for something smaller than a set screw type
    connector.
    Soft copper tubing,crimped with a hammer type
    swage tool, and covered with heat shrink?
    I've done it once or twice, even on heavy equipment battery cables as a "get it going" fix. You want a good tight crimp, push the cable together as tightly as possible before the second crimp.

  3. #3
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    Jun 2016
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    by a resevior in north central ar.
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    160

    Re: Soft copper tube for butt splice

    I have and then drilled a 2 small hole in the copper at the crimp and then soldered it. shrink wrap, tape and then covered with wire harness loom cover and taped again

  4. #4
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    Soda springs,Id
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    Re: Soft copper tube for butt splice

    Why not just spend the extra $$ and buy a pair of twistlok welding cable connectors??
    Mike
    Ol' Stonebreaker
    "Experience is the name everyone gives to their mistakes"

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  5. #5
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    Jun 2017
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    Re: Soft copper tube for butt splice

    As long as you don't have to deal with osha it will be fine, those osha people seem to dislike electrical tape on welding leads, extension cords etc.
    NRA LIFE MEMBER
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  6. #6
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    Re: Soft copper tube for butt splice

    Quote Originally Posted by mla2ofus View Post
    Why not just spend the extra $$ and buy a pair of twistlok welding cable connectors??
    Mike
    I thought about that. I’d rather have a permanent connection that’s smaller and cheaper.

    Caveman, if OSHA were ever to inspect my home shop, spliced welding cables would probably be
    one of they’re lesser concerns.
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  7. #7
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    Re: Soft copper tube for butt splice

    You can buy shrinktube that's about as thick as lead insulation.
    Mike
    Ol' Stonebreaker
    "Experience is the name everyone gives to their mistakes"

    Miller 175 mig
    Miller thunderbolt ac/dc stick
    Victor O/A setup
    Makita chop saw

  8. #8
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    Mar 2017
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    Forest Grove OR
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    228

    Re: Soft copper tube for butt splice

    Yes it will work, but cross sectional copper content in the splice will be far less than the 2 conductors being joined, and 100% of the current has to pass through the splice to get from one conductor to the other. Like using a small diameter chain link in-line to join two big chains together. It will work, but you restrict current capacity. In actual use, it acts like an inline resistor, and will likely get warm/hot. Split bolts are ugly, but they bond both conductors directly together and little current goes through the bolt, there is no current capacity loss if the splice is tight.

    This is one of the "correct" in-line ways to do it :

    https://www.amazon.com/Easy-Splice-L.../dp/B008KMKESI

    No cross-sectional loss with a splice like this. You can then heat shrink it.
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  9. #9
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    ct.
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    Re: Soft copper tube for butt splice

    Quote Originally Posted by Chad86tsi View Post
    Yes it will work, but cross sectional copper content in the splice will be far less than the 2 conductors being joined, and 100% of the current has to pass through the splice to get from one conductor to the other. Like using a small diameter chain link in-line to join two big chains together. It will work, but you restrict current capacity. In actual use, it acts like an inline resistor, and will likely get warm/hot. Split bolts are ugly, but they bond both conductors directly together and little current goes through the bolt, there is no current capacity loss if the splice is tight.


    This is one of the "correct" in-line ways to do it :

    https://www.amazon.com/Easy-Splice-L.../dp/B008KMKESI

    No cross-sectional loss with a splice like this. You can then heat shrink it.
    Yeah,I did some calculating of cross sectional areas and you’re right.
    I wonder if I could solder cables in tube in such a way that space between cable ends
    was filled with solder, conducting current between the ends.
    Miller a/c-d/c Thunderbolt XL
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  10. #10
    Join Date
    Mar 2015
    Location
    Milwaukee, WI
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    250

    Re: Soft copper tube for butt splice

    Tweco TS-3040 copper cable splicer:
    http://www.airgas.com/product/Weldin...CABEgKwtfD_BwE

  11. #11
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    Jun 2017
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    Re: Soft copper tube for butt splice

    Quote Originally Posted by jpump5 View Post
    I thought about that. I’d rather have a permanent connection that’s smaller and cheaper.

    Caveman, if OSHA were ever to inspect my home shop, spliced welding cables would probably be
    one of they’re lesser concerns.
    I just wanted to throw that out just in case you were in a shop somewhere, my shop would be in the same boat , I'm sure!
    NRA LIFE MEMBER
    UNITWELD 175 AMP 3 IN1 DC MIG/STICK/TIG
    MIDSTATES 300 AMP AC MACHINE
    GOD BLESS AMERICA!
    “Freedom is never more than one generation away from extinction.
    We didn’t pass it to our children in the bloodstream".
    RONALD REAGAN

  12. #12
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    Mar 2017
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    Forest Grove OR
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    Re: Soft copper tube for butt splice

    Quote Originally Posted by jpump5 View Post
    Yeah,I did some calculating of cross sectional areas and you’re right.
    I wonder if I could solder cables in tube in such a way that space between cable ends
    was filled with solder, conducting current between the ends.
    Just flux it up real well with some copper pipe flux, drill a 1/8" vent hole in the tube where the wires butt, and solder away. Solder won't conduct as well, but you'll have greater overall cross section, so your joint will probably have the same resistance in the end. It also won't ever come loose, so you don't have to crimp the crap out of it, just enough crimp to keep it together.
    Everlast 350 EXT - Thermal Dynamics Cutmaster 52 - Rogue Fabrication M600 xHD tube bender
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  13. #13
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    Sep 2015
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    SE Pa
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    1,291

    Re: Soft copper tube for butt splice

    I’ve done a few times to lengthen cables on buss box welders.

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