How much bigger is Welding cable compared to building wire... I need accurate numbers, Thanx?

I need the area (in^2) so I can size long barrel crimp terminals to fit snuggly around and provide a efficient connection... The last group just trimmed some wire off to fit in the hole, That is not going to work for my standards...How much bigger is Welding cable compared to building wire... I need accurate numbers, Thanx?
Do you mean the AC line going to the welding unit, or the welding cable to the point of welding? The reason I am asking is because you are comparing it to building wire.


Welding cable is far thicker than building wire, and more than that it is not solid, it is stranded. Furthermore, it is especially stranded by far more strands to increase the flexibility. Welding cable is the ';Porsche'; of cabling. Typically, heavy gauge like 0 or 00 is used, occassionally as thin as #2. But the essential factor is the amount of current it will carry. You can't expect an exact answer because you never mentioned current. Look in the phone book and call a welding supply store. They will tell you what gauge should be used to replace cabling. You can also look in a home improvement store, at welding equipment, the current capacities, then see what gauge they used. Notice how flexible the cabling is - not at all like building wire, or cheap jumper cables. To crimp onto welding cabling you will need expensive crimpers. Manual types will cost a few hundred each, hydraulic is best but costs far more. Or, you have them crimped by a shop that deals with heavy cable - batteries, forklift dealers, etc. Why in the World are you comparing welding cable to building cable?How much bigger is Welding cable compared to building wire... I need accurate numbers, Thanx?
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