Changing leads on a stickmate

[kendall]

I'm wanting to increase lead length on my stickmate. It has 4 awg size now. How long could I run this size? Should I get 2awg? Wanting to get to 50'

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[Oldendum]

Is that 50 feet total, or 50 ft ground lead and 50 foot electrode lead? I would go with 2 AWG. Pick a chart, any chart:

[kendall]

That's what I needed, thanks! 2 it is.

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[Iain P]

One thing I like to do is put quick connectors on the 2awg wire and put ~10ft of 4awg on the stinger. The 4awg is a lot lighter so it doesn't drag the stringer down as much.

[Oldendum]

Good idea on the lighter whip, especially if the existing #4 is still in good shape. If the whip gets cut or melted, no big deal.

Inexpensive sources of cable are TEMCo (on Amazon) and Electron Beam Technologies (prices and monthly specials listed on Facebook).

[kendall]

One thing I like to do is put quick connectors on the 2awg wire and put ~10ft of 4awg on the stinger. The 4awg is a lot lighter so it doesn't drag the stringer down as much.

Great idea!

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[Pete.S.]

You might want to consider changing your fixed leads to dinse connectors on the machine.
Then it's easy to change the length of your leads and you can also buy pre-made whips and extensions.

[kendall]

You might want to consider changing your fixed leads to dinse connectors on the machine.
Then it's easy to change the length of your leads and you can also buy pre-made whips and extensions.

This is the best option I have seen so far. I'm going to do this for sure. And add 1/0 main leads with a #2 whip at the end.

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[Oldendum]

1/0 seems a bit overkill unless you have very long leads. 1 gauge would be easier to drag around.

Here's some current prices from Electron Beam technologies:

4g (23 mm sq) EBT Part No. 46-PXL...... $0.78 per foot
2g (35 mm sq) EBT Part No. 69-PXL...... $1.13 per foot
1g (43 mm sq) EBT Part No. 84-PXL...... $1.38 per foot
1/0 (54 mm sq) EBT Part No. 107-PXL...... $1.75 per foot

[kendall]

I'm still waffling back and forth on what I need/want. The welder is on a cart and is fairly mobile. It would do fine as it is but longer leads would be nice. I will probably settle on 2ga 50 feet (ground and stinger combined length. Then keep the 15 ft 4 GA whip at the stinger.

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[Pete.S.]

I'm still waffling back and forth on what I need/want. The welder is on a cart and is fairly mobile. It would do fine as it is but longer leads would be nice. I will probably settle on 2ga 50 feet (ground and stinger combined length. Then keep the 15 ft 4 GA whip at the stinger.

Sounds reasonable. I think larger than 2ga is overkill.
I wouldn't bother with a smaller 4ga lead though. We have 2ga at work and if you buy good quality leads they are smooth and easy to work with. We have about 30 ft on both stinger and ground clamp. It also came with 4ga leads but not as good quality as the ones we have now.

[kctgb]

I had a job that needed longer leads on the welder, I took 25 foot number 4 cables for a Miller and clamped the ground to one end and the stinger to the other end. It worked fine, I'm sure OSHA would have a melt down.

[akcooper9]

Sorry to dig up a 4 year old thread but this seemed like the most relevant thread I could find.

I have a 160 amp IGBT stick welder with a 60% duty cycle. I am 100 percent a home hobbyist. If I read the chats above correctly, I am good with 4 AWG for 70FT of total lead length correct? Doesn't matter if the stinger is 50ft and ground clamp is 20ft or any other combination such as 35/35 split correct?

[G-ManBart]

Sorry to dig up a 4 year old thread but this seemed like the most relevant thread I could find.

I have a 160 amp IGBT stick welder with a 60% duty cycle. I am 100 percent a home hobbyist. If I read the chats above correctly, I am good with 4 AWG for 70FT of total lead length correct? Doesn't matter if the stinger is 50ft and ground clamp is 20ft or any other combination such as 35/35 split correct?

Correct....total length is all that matters, not how you proportion that length.