Switching out the ground cable.......

[Steve]

Ok...I have the Weltec 25 foot 20 series flexible torch. Really nice.

But.....I was still stuck with being 10 feet from the Powertig 250EX because of the grounding cable. And the pedal cable is 15 feet so that will have to be changed out too!

So I decided to switch out the ground cable. Went to Tractor Supply and they have 1/0 welding cable so I bought 25 feet of that along with a new cable eye end.

I figured out that you have to pry the factory dinse cover away by heating it up with a hand held hair dryer and gently pry the rubber cover off the dinse connection. It will slide down the cable when it is free.

You then will have to remove the cable from the male metal end of the dinse with the allen head screw. The cable will just pull out.

You will notice that there is a ferrule wrapped around the cable as it is doubled over to make for a really good connection. It has a split in it and can easily be bent away from the cable. Pull the cable out and then unbolt the other end of the cable to the ground clamp.

Then take the new cable, strip off about 1 inch of the insulation from the end. Add the eye connector and bend over the cable for the dinse end. Make sure you put the cover over the cable before you put the ferrule and dinse on. Tighten the allen head over the inserted ferrule/cable. Then slide the rubber dinse cover back over the brass end and you are done.

It is really easy and allows for the re-use of the factory dinse ground connector. It's really nice to be able to move around the shop without having to worry about being stopped by the ground cable. Next project is a new SSC foot control pedal and longer 25 foot cable.