CK 200 Torch to 250EX with Photos and Part #'s

[Rugar]

Here is a list of part #'s along with photos to adapt a CK 200 torch to a Everlast 250EX with a Powercool W300 water cooler. All parts were purchased through Jim Watson over at http://www.arc-zone.com/

Torch used was CK 200 Flex Neck
Part# CK-225SF FX 250A Water Cooled Flex Head Torch Package With 25' (7.6m) Super Flex Cables.

Soft Leather Cover for torch leads
Part# CK-225HCLV
Leather Cable Cover w/ Velcro. 23' (7.0m) x 3-3/4" (95.2mm). Durable, Flame Resistant, Light Weight & Abrasion Resistant. For 9 & 20 Series Torches.

Photo showing torch, leather cover, and how flexible the lead is.


Photo comparing the CK 200 to the stock Everlast torch.


Dinse Connector: The rubber cover had to be slightly trimmed for the dinse to fully seat into the Everlast machine (1/4" or so), because of the lip on the machine where the connector plugs in. Took about 2 mins, with a razor blade. This is a Miller style connector. According to Jim, a Lincoln style will plug in without any mods. No big deal either way.

Part# Q5W Large Male Water-Cooled Connector -- International Dinse Style with
Adjustable "Red" Water Return Hose. For TIG Power Cables with 7/8" x 14 Left Hand Threads.


Water and gas connectors:
Torch comes with two 5/8" male LH thread water connectors, and a 5/8" male RH gas connector already factory installed.

Water:
I had Arczone make me a 12" extension hose for the water outlet on the dinse connector, to the water input on the cooler to make it long enough. I have my welder and cooler on a Everlast cart. (mine is 12" of hose plus fittings)

Coupler to fit 5/8" male LH water connector on dinse hose.
Part# WES-AW-431 (11N18)
Water Coupler, 5/8" LH Female to 5/8" LH Female "B" Type

To fit hose and coupler.
WES-AW-14 (136Z08)
LH Nut, Water -- 5/8" x 18 LH Thread

Part# WES-AW-17
1/4" "B" Size, Long Barbed Hose Nipple.

Part# FAL-500
Ferrule, Aluminum

Extension hose.
Part# A-BVT-4
1/4" (6.4mm) I. D. x 7/16" (11.5mm) O. D. High-Quality Black Vinyl
Tubing -- ( Sold in 1' sections




Quick connect on end of extension hose for cooler input.
Part# A-QCHP14
Water Plug Male with 1/4" Barbs.






Water output on the cooler to input on the torch was the easiest.
Part# ZHCK-W
Water Converter -- 5/8" LH Female -to- Quick-Release (QRW Male Plug)





Continued in next post. Board will only let me post 10 photos per post.

[Rugar]

Gas:
Since Everlast uses the same water type connectors for the quick releases on both water and gas lines to the machine and cooler (atleast mine does), a short adapter hose has to be made (mine is 4" of hose plus fittings). The problem is that water fittings are LF thread, and gas fittings are RH thread. So you need a way to change the RH thread fitting that comes factory on the torch over to a water type connector which only comes in a LF thread.

RH thread coupler to factory RH thread on torch.

Torch hose end of gas connector:
Part# WES-AW-430 (11N17)
Gas Coupler, 5/8" RH Female to 5/8" RH Female "B" Type

Part# WES-AW-14A (105Z83)
RH Nut, Gas 5/8" x 18 RH Thread.

Part# WES-AW-17
1/4" "B" Size, Long Barbed Hose Nipple.

Part# FAL-500
Ferrule, Aluminum

Part#A-BVT-4
1/4" (6.4mm) I. D. x 7/16" (11.5mm) O. D. High-Quality Black Vinyl
Tubing -- ( Sold in 1' sections (same hose as used on water lines)

Machine end of gas connector: (same fitting as water input on cooler)
Part# A-QCHP14
Water Plug Male with 1/4" Barbs.







With these parts you should be able to hook up any manufactures water cooled torch to your machine as long as it has 7/8" x 14 LF threads for the power cable, and 5/8" threads for the water and gas hoses.






Everything came out to a little over $300 including parts, sales tax, shipping, and having Arczone assemble the hose extentions with the really nice clean crimps for the hose ends.

I also have another 24" hose extention I had them make up for a water line complete with a water coupler for the torch end, and a quick connect for the cooler end that was not needed. Let me know if anyone needs it.

If you have any questions or need any more photos just let me know.

[ciscotex]

Gerald,

Thanks for taking the time to post all of the part numbers. I have not received my unit yet, but am planning to order from Jim so that it's here when the welder arrives.

In looking at the pictures, will the water cooler fit on the middle shelf of the cart? It looks like all of the hoses limit access to it anyway.

Also, having hooked it all up, are there any changes (hose lengths, etc.) you would make now that you've got it all hooked up?

Thanks in advance for your response,
Paul

[Rugar]

Gerald,

Thanks for taking the time to post all of the part numbers. I have not received my unit yet, but am planning to order from Jim so that it's here when the welder arrives.

In looking at the pictures, will the water cooler fit on the middle shelf of the cart? It looks like all of the hoses limit access to it anyway.

Also, having hooked it all up, are there any changes (hose lengths, etc.) you would make now that you've got it all hooked up?

Thanks in advance for your response,
Paul

Paul,
The cooler is to tall to fit on the middle shelf. The cooler is around 13" tall, and the rear height of the middle shelf is only around 9". I have plastic fishing tackle storage box for my consumables on the middle shelf along with my TIG only wire brushes and welding hood. And yes the hoses do kinda limit access to it. If the top shelf on the cart was about 5 or 6" higher, the cooler could be on the middle shelf and you would then have have access to the bottom one with a lot more storage space. This is the cart that Everlast sells, and is fairly sturdy even with my huge heavy 330cf bottle on it. The way the front handle on it mounts is kinda weak though. It was worth what I paid for it, but eventually I'm going to make a custom one out of aluminum, if for nothing else, just a project.

As far as hoses, the water line extension hose from the torch to the cooler input could have been maybe 3 or 4" longer. Mine is a 12" long hose plus the length the brass fittings add to it. Its not under any stress or anything, but I wouldn't want it any shorter. A little longer, but not by much, would just give a little more of a clean custom look. (I'm a little to anal when it comes to things like this)
The gas extension adapter hose is almost perfect (at 4" of hose plus fittings), but even if was 2" of hose it would have been fine. I just told Jim to make it as short as possible, and a 4" long hose is what he used.

After playing around yesterday for awhile, it just blows my mind how much more torch control I now have with this setup. The lightness of the torch, and the flexibility of the torch lead is just unbelievable. This is sure going to help out with the learning curve as a TIG newbie. Now I'm just wondering how much difference a aftermarket pedal setup like Steve did would help out. I'm finding I really love working with the super thin intricate materials.

[ciscotex]

Gerald,

Thanks for the quick reply. You addressed absolutely everything I was wondering about. And yes, I asked because you've done such a thorough job of addressing exactly the same issues I want to.

By way of introduction, I've been in an intro TIG class at the local CC for the past semester and am taking advanced TIG in the spring. I've been using a 20 series torch all fall and love it. Don't want anything bigger/heavier. I need every edge I can get to fend off the damn whippersnappers with their sharp eyes and lack of the palsy. Buying the machine to practice at home. I need it, but I'm getting better.

Re the footpedal, after all the noise, I'm eyeing Steve's solution as well, but am going to try the OEM Everlast pedal first. I was using a Dynasty 200 at school and don't know if it was the pedal (which I believe is made by the same folks that made Steve's), the Dynasty, or just the sensitivity of the puddle to slight changes in heat, but it seemed to not have a linear response. Whether it had an audio-style taper pot, I don't know, but from wide-open, a very small movement had a large effect on the puddle, and didn't feel linear. Could just be my poor skills. Are you aware of any source for the 7 pin plug for the footpedal yet?

Anyway, I apologize for the hijack and the mods are free to move this rambling discourse to a pedal thread if they choose.

Thank you again for taking the time both in your original post, and your follow-up to my question.

Paul

[Rugar]

No problem on the hijack. I didn't even consider it as such.
I haven't even looked for a 7 pin connector. I did order the one from E-Bay that Jake posted the link to in another thread, but according to a few its the wrong pin and diameter size. Will know more once it gets here. Its on a slow boat from China. I just asked Ray tonight in Steve's pedal thread if he had any luck finding one yet. I'm not really wanting to cut the connector off my stock pedal, just in case I don't like the replacement for some reason, or just need it for a spare. The stock pedal seems to work alright, but I feel it could be a little more linear on really low amp settings doing really thin material.

[jakeru]

Hey Gerald - kinda funny your CK torch handle says "CK 200 RIGID" despite it being a flex-neck. Gotta love those CK "superflex" hoses!

Anyway I can confirm those 7-pin connectors I linked on Ebay and had Ray send me, do indeed fit my ~3-year old Everlast Super200P perfectly. (However unfortunately if what Mike said about the older everlast macines using a different connector than the new ones is true, then that may be sort of a confirmation that they won't fit the newer machine.) Nice torch upgrade write-up, and cheers!

[Ray]

Jake,
Glad you can use the connectors, they won't fit the newer machines for sure. Still no word from Greybar, they had the same connector.
Hope to come up with something soon.

[Rugar]

Hey Gerald - kinda funny your CK torch handle says "CK 200 RIGID" despite it being a flex-neck. Gotta love those CK "superflex" hoses!

Anyway I can confirm those 7-pin connectors I linked on Ebay and had Ray send me, do indeed fit my ~3-year old Everlast Super200P perfectly. (However unfortunately if what Mike said about the older everlast macines using a different connector than the new ones is true, then that may be sort of a confirmation that they won't fit the newer machine.) Nice torch upgrade write-up, and cheers!

Ya, its a flex neck from CK's "Rigid" line of torch's. Does seen sorta weird.

I got the e-bay 7 pin connectors in yesterday, and can confirm that they are way to small.

Thanks for the compliment on the write up.

[angular]

Very good stuff, Rugar. Thanks for the detailed write-up. I'm very new to all this so I don't want to "blame the instrument" (so to speak) but I think it would help me to upgrade to a smaller and easier to use torch than what came with the 250EX. Sounds like a gas lens is a good idea too.

[angular]

UPS just delivered my CK-200 package from Arc-Zone! I can't believe how skinny the cables are! Amazing. I'm headed home now and will try it out tonight. I sure wish they would have included a full size back-cap, though. I didn't think to order one.

[Zoomie]

Did Arc-Zone pre configure the connectors etc for you or will it be something you have to tackle?

[angular]

Arc-Zone can make whatever you need. They made a gas adapter cable for me like they did Rugar. For the water connections, I just asked for some 5/8-18 to 1/4" NPT adapters because I am not using the Everlast W300 cooler.

I'll see if I can get some pictures posted in the next hour.

[angular]

Here are a few pics! Thanks again to Rugar for starting this thread and Arc-Zone for their great customer service.

[Nikola Tesla]

I love arczone. Almost as much as I love everlast. Is that better everlast? lol. Thanks for all the ideas. I make my money stretch as far as I can. Not because I am a cheap skate, but because I am broke. lol. Arczone also sold me some weldcraft rare earth tungstens. As I am just learning I have nothing to compare it to. However, they seam to work great from everything I have read of all the problems with tips.

[Rugar]

Here are a few pics! Thanks again to Rugar for starting this thread and Arc-Zone for their great customer service.

Your welcome Angular.
Glad to hear this thread is helping people out.
Does look like they made the gas converter hose a little long at 12" though in the final kit form. That hose only needs to be ( at least on my setup) long enough to get fittings on both ends.
Did you also get a leather hose cover?
You wil also need to trim about 3/16" off the the rubber cover for the Dinse connector on the machine end to get it to fully seat into the machine. I just used a razor blade.

[Rugar]

UPS just delivered my CK-200 package from Arc-Zone! I can't believe how skinny the cables are! Amazing. I'm headed home now and will try it out tonight. I sure wish they would have included a full size back-cap, though. I didn't think to order one.

You can get a full length back cap from your LWS for just a couple bucks.. The 20 series torch's all use the same cap so any brand should fit. I think the extras I got from my LWS are weldcraft. They screw right on to my CK torch.

[angular]

Yep, I ordered the soft leather cable cover too. That's the only thing not in the picture.

That's that I was thinking... stop by a welding supply shop today and pick up a full size back cap.

[Salty]

Rugar , I know this is an older post but do you still have that 24 " extention hose? I am going for the same torch upgrade and I think the 24" length will be good for my set up.

[Rugar]

Rugar , I know this is an older post but do you still have that 24 " extention hose? I am going for the same torch upgrade and I think the 24" length will be good for my set up.

Yes I still have it laying on the shelf. How about $20 shipped for the hose and coupler?