How to Weld a Cable Joint

The point where two cables are connected is known as a cable joint. A connection is made between two cables through a variety of methods, including welding. Welding is the process of joining two pieces of metal together by melting them with an electric arc, or flame. Welding the cables together results in a bond much stronger than a plastic cable tie or electrical tape.

Steel wool pad
Clean cloth
Mild detergent
2 table-mount vise grips
Arc welder with AC output
Welding rod
Welder’s mask
Welding gloves

Instructions

- 1
  Rub the cables with steel wool to remove any rust. Clean the cables with a cloth soaked in warm, soapy water. Allow the cables to dry completely.
- 2
  Mount two vise grips on a work table, spaced between 1 and 2 feet apart.
- 3
  Lock one cable into each vise grip. Position the cables so they overlap one another by at least 1 inch.
- 4
  Put on welder’s gloves and a welder’s mask.
- 5
  Insert the welding rod into an arc welder with alternate-current output. Set the welder to the welding rod’s specified electrical current, located on the packaging.
- 6
  Angle the welding rod at a 35- to 45-degree angle. Touch the tip of the welding rod above the cables where they overlap. Move the welding rod along the surface of the overlapping cables in a motion similar to striking a match. You should see the cables begin to weld together.
- 7
  Rotate the cables in the vise grips and weld around the entire perimeter.

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