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.

[Rugar]

Nice alternative cable cover Jakeru. Thats thinking outside the box.
Is that a Everlast paddle switch, or one of the E-bay ones? Ive been wanting to add a switch to my CK torch as well, but as far as I know no one has of yet been able to come up with the larger 7 pin connector to fit my 250ex. I'm not sure if the one from Everlast has the small 7 pin that fits yours, or the larger one.

[Ram48]

Jake
That looks great What is the cover made of?
Can you let us know where to get some?
I would have a few uses for that in my shop and projects

[presure2]

looks good jake, like the others have posted, more details would be awesome, got a link?

[Ram48]

Here are two links for the sleeve.
http://cableorganizer.com/wire-management/
http://www.everlastgenerators.com/fo...8299&noquote=1
http://www.techflex.com/

If you Google expandable sleeving you get a ton ore quite a product line that ranges from abrasion resistance to heat protection to 1800 deg.
Heck I even found it in Everlast Green.

[jakeru]

I got the expandable tubing from my local electronics supplier. They sell it by the foot and let me take home a few samples of different similar products, so I could test the fit and buy the one I liked best. (they were also surprisingly reasonable on price.) I just went with the standard 1/2" expandable product, which comes in different colors (and my wife talked me into getting yellow ) It expands a bit fitting over my cables, and in doing so, shrinks in length, so I am sure I got a longer piece of it than I had TIG torch line. Keep this in mind if you mail or internet order it.
http://shop.vetcosurplus.com/catalog...ducts_id=11417

They had some nice looking split mesh sleeving product that would be really easy to install over the cables and had decent flexibility, but in the 1/2" size it looked like it was going to split open and let the bundle out, while in 3/4" size it looked too bulky so it just wasn't available in a good size.

The expandable 3/4" size fit nicely over my TIG leads in a straight line, (and installed a little easier, didn't need as much expanding) but I found that to flex it the diameter would need to grow to provide the flexibility, which I think would be kind of annoying having a bulbous section of expandable sleeving at the end of the torch handle where it flexes the most. The 1/2" expandable product worked better for my bundle size, because the fibers would partly expand during installation and allow more flexiblility while staying tight to the bundle.

McMaster Carr also has a lot of different kinds of sleeving products
http://www.mcmaster.com/#sleeving/=bpc943

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Update:
I got the TIG Torch expandable sleeving fully installed and the torch switch is now fully operational. I used some high voltage rubber splicing tape to keep the ends from getting frayed. (Cutting the ends with a "hot knife" instead of scissors also helps to keep it together too.

I tested the new torch switch out to fill a large hole, about 1/2" in a square aluminum extrusion, 1"x1" by about .065" thick with a thin filler rod. It was an operation I knew I would need good torch manipulation and heat control to pull off. I just dialed in about 40 amps peak, and about 2 seconds of downslope, and varied the switch press vs release while in 2T mode to control the heat. Worked beautifully! Added layer upon layer of filler to close the hole completely, with ease. I don't think a footpedal would have let me do it much better.

It's great to have an operational torch switch again!

Oh by the way this torch switch was the original one off the WP-17 torch that came with my Everlast Super200P. But I do believe I've seen the same ones recently for sale on Ebay.