Adding DINSE Style Quick Disconnects to Lincoln AC-225

I was inspired by Gregory Hildstrom to do some upgrades to my Lincoln AC-225.  The first is to add some quick disconnects to the front panel.

Parts List

Quick Fitting Cable connector-Plug + Socket DKJ10-25 & DKZ10-25 $1.60 x 4 = $6.40 + shipping

3/4″ Forstner drill bit (I used this since it’s what I had at the time.  I recently started using stepped drill bits for things like this and they are MUCH better!)

Drill

Small file

Allen wrench

Work

The first step was opening it up and adding quick disconnects to the front panel.  I found some cheaper DINSE-style connectors that set me back about $15 for four male and four female from River-Weld.  They aren’t as solid as name brand connectors and are only “rated” up to 200 amps, but they should work fine for me.

I also found a post and also a video on doing this that was helpful.  The video goes into the upgrade in-depth and he also explains the importance of keeping the panel connector separate from the body.

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Schematic from the welder

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Using a Forstner drill bit to cut a 3/4″ hole in the front panel

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The front of the connector goes through and the notch at the 2 o’clock position keeps it from rotating when installed

 

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Hole cut and notch ground with a file

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The brass insert comes in from the front, a washer and nut secure it from the back, and a bolt will hold the lugs on

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I kept the original holes in the front for the AC connection and will wire the other two for DC

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Welding lead cut and stripped

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Copper collet attached that comes with each connector

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Adapter placed over the collet

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…and tightened down

Outcome

They aren’t as strong or feel as secure as ones on 100% duty cycle machines I’ve used, but for my garage and the 2x a year I’ll use it, they should do fine!

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The first two connectors installed

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All four connectors installed and labeled

All four connectors installed and labeled

The next step is adding DC outputs.

Sources

http://weldingweb.com/showthread.php?141101-removable-leads-for-Lincoln-tombstone

http://hildstrom.com/projects/ac-225/

 

Posted in Welding
One comment on “Adding DINSE Style Quick Disconnects to Lincoln AC-225
  1. Monte says:

    Nicely Done! Gonna do the same thing to my tombstone…

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