Expandable Sleeving on TIG Torch cables

[jakeru]

I wanted to share the latest improvement I am attempting on for my TIG welding setup.

I have a CK Worldwide aircooled torch with "one-piece" superflex hose. I wanted a cable cover to protect this nice hose from abrasion when dragging it over any sharp workpiece edges or across the floor. I also wanted to add a switch to the torch (and that means running some wiring alongside the cable) onto the torch handle that my original everlast (WP-17) torch had. I found the original WP-17 torch switch was really handy for out of position welds (for example, welding patch panels onto car bodies.) I also found the large paddle style switch easy to operate.

Although I've never seen it done before, I was attracted to trying an "open-weave" type sleeve for this application, because I figure it might increase the power & duty cycle of the torch/cable over a solid tubing type cover, by allowing the cable to somewhat "breathe" to stay cool. It might also allow light weight, lots of flexibility, and stay low profile / tight to the cable. I bought a common type of expandable tubing to try out, made of polyethylene I believe. Supposedly this material is rated for 257 degrees F, which is about 50F hotter than the original vinyl tubing sleeve material is rated for. (I will still try to keep it away from hot, just welded parts, to give it a fighting chance.) I tried some different diameters of the expandable sleeving before settling on 1/2" nominal size, which seemed to allow the most flexibility for the bundle size I will be using.

I will also be running wires in the sleeving for a torch switch I will be installing. I drilled a hole in the butt end of the handle (keeping at least about 1/4" away from the electrically "hot" brass connector inside there) to allow the torch switch wires to nearly neatly through from the inside of the handle to the outside to reach the switch. The switch will be ziptied onto the handle, a feature I liked about the original everlast WP-17 torch setup because it allows easy and convenient switch repositioning for easiest switch access.

Just wanted to share.