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Thread: Welding lead capacity

  1. #1
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    Welding lead capacity

    I'm looking to buy some welding lead reels and new leads for my truck, I can't get a straight answer to the ampacity of the welding leads at different lengths, I want to have 150ft leads total, 75ft on each reel, I rarely even weld with 1/8 rod, but I want to be able to, I also run a spool gun off the truck too, not sure what the amps are when I'm running that.

    Will #1 welding wire work for that?

    I could go 1/0 but I'm trying to save on cost


    Every different chart I see has a different number seems like when it comes to Max length for fifteenth lead sizes


    Thanks

    Sent from my SM-G973U using Tapatalk

  2. #2
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    Re: Welding lead capacity

    Quote Originally Posted by MetalMan23 View Post
    I'm looking to buy some welding lead reels and new leads for my truck, I can't get a straight answer to the ampacity of the welding leads at different lengths, I want to have 150ft leads total, 75ft on each reel, I rarely even weld with 1/8 rod, but I want to be able to, I also run a spool gun off the truck too, not sure what the amps are when I'm running that.

    Will #1 welding wire work for that?

    I could go 1/0 but I'm trying to save on cost


    Every different chart I see has a different number seems like when it comes to Max length for fifteenth lead sizes


    Thanks

    Sent from my SM-G973U using Tapatalk
    I would go with1/0 since you indicated using a spool gun. It's nothing to get in the 200-250 amp range on heavier aluminum. Same deal if you ever decide to using larger self shielded wire.

  3. #3
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    Re: Welding lead capacity

    That is true, I didn't think about the dual shield, .045 or 1/16, I don't want to have to buy all new leads if I want to add that capability in the future

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  4. #4
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    Re: Welding lead capacity

    Quote Originally Posted by MetalMan23 View Post
    I'm looking to buy some welding lead reels and new leads for my truck, I can't get a straight answer to the ampacity of the welding leads at different lengths, I want to have 150ft leads total, 75ft on each reel, I rarely even weld with 1/8 rod, but I want to be able to, I also run a spool gun off the truck too, not sure what the amps are when I'm running that.

    Will #1 welding wire work for that?

    I could go 1/0 but I'm trying to save on cost


    Every different chart I see has a different number seems like when it comes to Max length for fifteenth lead sizes


    Thanks

    Sent from my SM-G973U using Tapatalk
    Phil, you advertise that you repair heavy equipment. That #1 wire will really limit you. What size engine drive do you use? Now for me and only me I use 50' 2/0 as my pull offs on the truck and use various whips from 10' - 25'. My 10's are 2/0 and #1 with my 25' being #1. But a few times a year I have to drag out my 100' 2/0's and once a year I have to use it all. 150' of 2/0 with my 25' #1 whips for a total of 175' for stick. For shielded flux and flux I'm limited to 150' but that has worked out for years running up to 5/64ths wire. Now a few times a year I just use my 25' #1's when I fiddling on my truck bench or right next to it with stick.
    Last edited by Freebirdwelds; 05-27-2022 at 03:26 PM. Reason: Speeling
    Lincoln 330MPX
    Lincoln Power Mig 256
    Lincoln LN-25X Wire Feeder
    Magnum PRO 250LX GT Spool Gun
    Lincoln AC/DC 225
    Ton of Torches OFC-A OFG-A
    Air Carbon Arc Gouging
    CAC-A
    Everlast 62i Plasma Cutter
    Ingersoll Rand T-30 14hp
    Instagram: #Freebird Welds

  5. #5
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    Re: Welding lead capacity

    Lincoln Ranger 225

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  6. #6
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    Re: Welding lead capacity

    Here's what Miller recommends:

    Name:  Capture.jpg
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Size:  79.8 KB
    Miller Multimatic 255

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  8. #7
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    Re: Welding lead capacity

    You do know the cost is over $1,000.00 for each cord.

    Dave

    Quote Originally Posted by MetalMan23 View Post
    I'm looking to buy some welding lead reels and new leads for my truck, I can't get a straight answer to the ampacity of the welding leads at different lengths, I want to have 150ft leads total, 75ft on each reel, I rarely even weld with 1/8 rod, but I want to be able to, I also run a spool gun off the truck too, not sure what the amps are when I'm running that.

    Will #1 welding wire work for that?

    I could go 1/0 but I'm trying to save on cost


    Every different chart I see has a different number seems like when it comes to Max length for fifteenth lead sizes


    Thanks

    Sent from my SM-G973U using Tapatalk

  9. #8
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    Re: Welding lead capacity

    Quote Originally Posted by smithdoor View Post
    You do know the cost is over $1,000.00 for each cord.

    Dave
    here are some decent prices on flex-a-prene.

    https://www.harrisweldingsupplies.co...e-cut-lengths/
    Lincoln 330MPX
    Lincoln Power Mig 256
    Lincoln LN-25X Wire Feeder
    Magnum PRO 250LX GT Spool Gun
    Lincoln AC/DC 225
    Ton of Torches OFC-A OFG-A
    Air Carbon Arc Gouging
    CAC-A
    Everlast 62i Plasma Cutter
    Ingersoll Rand T-30 14hp
    Instagram: #Freebird Welds

  10. #9
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    Re: Welding lead capacity

    Quote Originally Posted by MetalMan23 View Post
    Lincoln Ranger 225

    Sent from my SM-G973U using Tapatalk
    here is what Lincoln recommends for welding cable. It's best to stick with the 100% duty cycle ratings if you can.

    https://www.lincolnelectric.com/en/w...welding-cables
    Lincoln 330MPX
    Lincoln Power Mig 256
    Lincoln LN-25X Wire Feeder
    Magnum PRO 250LX GT Spool Gun
    Lincoln AC/DC 225
    Ton of Torches OFC-A OFG-A
    Air Carbon Arc Gouging
    CAC-A
    Everlast 62i Plasma Cutter
    Ingersoll Rand T-30 14hp
    Instagram: #Freebird Welds

  11. #10
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    Re: Welding lead capacity

    This is out of the manual for my 330mpx.

    Name:  Image1.jpg
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    Lincoln 330MPX
    Lincoln Power Mig 256
    Lincoln LN-25X Wire Feeder
    Magnum PRO 250LX GT Spool Gun
    Lincoln AC/DC 225
    Ton of Torches OFC-A OFG-A
    Air Carbon Arc Gouging
    CAC-A
    Everlast 62i Plasma Cutter
    Ingersoll Rand T-30 14hp
    Instagram: #Freebird Welds

  12. #11
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    Re: Welding lead capacity

    I have the same length cables as what you are wanting, I plan on stick only with a max of 1/8" so I went cheap and got #2 leads. Same kind of work you're doing. If it was in the budget I would have gone 1/0 just for the occasional air-arc job. I used the same charts the guys posted above. I know already that I'm not going top be working it anywhere near capacity or duty cycle.
    Use a bigger hammer.

  13. #12
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    Re: Welding lead capacity

    I was talking about cord winded up reel .
    But cord is not cheap too.

    Dave

    Quote Originally Posted by Freebirdwelds View Post
    here are some decent prices on flex-a-prene.

    https://www.harrisweldingsupplies.co...e-cut-lengths/

  14. #13
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    Re: Welding lead capacity

    Quote Originally Posted by smithdoor View Post
    I was talking about cord winded up reel .
    But cord is not cheap too.

    Dave
    Gotcha.
    Lincoln 330MPX
    Lincoln Power Mig 256
    Lincoln LN-25X Wire Feeder
    Magnum PRO 250LX GT Spool Gun
    Lincoln AC/DC 225
    Ton of Torches OFC-A OFG-A
    Air Carbon Arc Gouging
    CAC-A
    Everlast 62i Plasma Cutter
    Ingersoll Rand T-30 14hp
    Instagram: #Freebird Welds

  15. #14
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    Re: Welding lead capacity

    Maybe a backpack gasoline welder would be cheaper. Would a good workout too.

    Dave

    Quote Originally Posted by Freebirdwelds View Post
    Gotcha.

  16. #15
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    Re: Welding lead capacity

    Quote Originally Posted by smithdoor View Post
    I was talking about cord winded up reel .
    But cord is not cheap too.

    Dave
    https://store.cyberweld.com/diamond-...%2BKh*e-RGFqwS

    That's what I'm looking at

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  17. #16
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    Re: Welding lead capacity

    Looks great 👍.

    This type I am use too. But your is a lot better
    https://www.mcmaster.com/7353K416/
    FYI I only purchased for Doors upto 150 foot long. Never would buy one for my work

    Dave

    Quote Originally Posted by MetalMan23 View Post
    https://store.cyberweld.com/diamond-...%2BKh*e-RGFqwS

    That's what I'm looking at

    Sent from my SM-G973U using Tapatalk
    Last edited by smithdoor; 05-27-2022 at 10:51 PM.

  18. #17
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    Re: Welding lead capacity

    Quote Originally Posted by MetalMan23 View Post
    https://store.cyberweld.com/diamond-...%2BKh*e-RGFqwS

    That's what I'm looking at

    Sent from my SM-G973U using Tapatalk

    Cheaper and with free shipping.

    https://www.harrisweldingsupplies.co...ng-lead-reels/

    .
    Lincoln 330MPX
    Lincoln Power Mig 256
    Lincoln LN-25X Wire Feeder
    Magnum PRO 250LX GT Spool Gun
    Lincoln AC/DC 225
    Ton of Torches OFC-A OFG-A
    Air Carbon Arc Gouging
    CAC-A
    Everlast 62i Plasma Cutter
    Ingersoll Rand T-30 14hp
    Instagram: #Freebird Welds

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  20. #18
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    Re: Welding lead capacity

    Little tip. You can get the cable they use for welding leads at electrical supply stores that have cable.
    Gear: Esab power compact 205 with tbi industries torch
    BOC Smootharc 185dc tig
    Miller Syncrowave 350LX

  21. #19
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    Re: Welding lead capacity

    These are realatively short and just cause a guy hooks wire,,, (especially spool gun) to it doesnt mean its going balls out. I like 1, so much easier to handle and you got to be hanging off the edge to over work it. If you are concerned about needing heavier,,, you wont. If you know you need heavier now then its different. You can air arc with it,,, just cant do huge steady. Your machine will be a smoldering cinder before you overwork 1.

  22. #20
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    Re: Welding lead capacity

    Quote Originally Posted by William Payne View Post
    You can get the cable they use for welding leads at electrical supply stores that have cable.
    Phil,
    Valley Electrical in Ansonia has welding cable in bulk.
    203-734-1635
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  23. #21
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    Re: Welding lead capacity

    I buy all of my new lead from www.electronbeam.com

    Their lead is top quality, and always the best prices.
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  25. #22
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    Re: Welding lead capacity

    Quote Originally Posted by Louie1961 View Post
    Here's what Miller recommends:

    Name:  Capture.jpg
Views: 332
Size:  79.8 KB
    Louie, that clears things up nicely!

  26. #23
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    Re: Welding lead capacity

    I agree
    It is very good chart .

    Dave

    Quote Originally Posted by Cobraone View Post
    Louie, that clears things up nicely!
    Quote Originally Posted by Louie1961 View Post
    Here's what Miller recommends:

    Name:  Capture.jpg
Views: 332
Size:  79.8 KB

  27. #24
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    Re: Welding lead capacity

    Miller has a lot of great charts and things like that that are really helpful. They even have a neat slide rule you can buy where you set what type and thickness of material you want to weld and what type of join and it gives you a rough idea on what your setup should be depending on what process you are doing.
    Gear: Esab power compact 205 with tbi industries torch
    BOC Smootharc 185dc tig
    Miller Syncrowave 350LX

  28. #25
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    Re: Welding lead capacity

    You have a good sense of practicality and came to a good conclusion. Don't let that good sense be shaken by obsessive types. I might be inclined to put 85 or 90 ft on the stinger.
    Something else with modest lead and simple setup. I getva connector and a ground clamp and hook to the machine. For the stinger a connector and a electrode holder to start with. You can always add more before coming up with a scheme involving a couple of every connector they invented. Maybe lugs on machi e and males on leads but that stuff really grows and adds to cost.
    This was a revision,,,, removed all this from one circuit, just kind of grew over the years.

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