Custom-made welder cords can increase workshop safety.
Most welders are portable but come with 8- to 10-foot-long power cords that restrict their use, so an extension cord is required to extend their range. Using the right cord capable of handling the voltage and current demands of the welder is vital. Wiring your own extension cord enables you to produce a cord of the right length and electrical characteristics to meet your specific needs. It may also cost less than purchasing one.
Instructions
1. Disassemble the two new plugs. The fastenings may be screws or clips. Unscrew screws or pry off clips using an electrician's screwdriver, then place the top of the plug, and screws or clips, to one side in a safe location.
2. Feed a sufficient length of cord through the housing in each plug for you to work on the end of the cord without the plug housings getting in the way. Use a knife to strip the final 2 inches of outer insulation from each end of the cord to expose the individual wires. Do not damage the internal wire insulation as you do this.
3. Use a knife to bare the final 1/4 inch of each wire. Twist together each bundle of exposed wire filaments to stiffen them and create a rod.
4. Attach the wires to the plug terminals. Extension cords must use polarized wiring so be careful and double check your connections. Remember, the "hot" black or red wire goes to the brass terminal, the "neutral" white wire to the silver terminal and you attach the bare or green covered grounding wire to the terminal marked as GND.
5. Protect the terminal connections against being pulled loose from the plugs by fastening the cord in the cord grips. Confirm that the terminals are tight and the cord grip is secure and then replace the housing on each plug. Complete a visual inspection of the cord checking for any accidental cuts or damage to the insulation or plugs. The cord is ready for use.
