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Electrical Welding Wire

For Wind Turbine Towers

"Many wind turbine manufactures brag about their brushless PMA's and also admit to the terrible dependability of carbon brushed generators. Then they do something very puzzling, they install a set of carbon brushes in their slip rings assemblies! Is this not at odds with their own philosophy?"

  • "Carbon brushes can snap off like ice sickles in freezing weather"
  • Build your Wind Power System without ANY brushes!
  • Go totally brushless for your highest possible dependability factor!
  • No voltage loss with our brushless Wind Turbine design!
  • Use #6 Welding Cable For Your Wind Turbines
  • Power Transmission Going Down Your Tower ? Some customers on the coast connect their negative wire on the base of the tower and the towers are not showing any corrosion (weld nut to base and bolt negative wire to it)
  • "Slips Rings Are Out Dated Technology For Any Of The Newer Wind Turbines That Do Not Continually Furl To The Left Or To The Right"
  • With the advent of carbon fiber technology many newer wind turbine designs do
    not furl at all. They are simply built tough enough to take just about any wind speed.

#6 black welding wire cable

Black welding wire cable roll

#6 black welding wire cable

Note: #6 is the largest
wire that can be used in
1-1/2" galvanized pipe

#6 - 24 Feet of Welding Wire Cable (Extra Flexible) - RED

#6 - 24 Feet of Welding Wire Cable (Extra Flexible) - BLACK

Also, another option is to weld a nut to the bottom of the tower and connect the negative wire to it and run it to the battery disconnect box.

Note: You can use a #4 wire on the PMA for the positive lead (#4 is much much easier to find at you local welding shop). Then weld a nut to the bottom of the tower and connect your ground wire there. Coat it for corrosion protection.

Here are all the good reasons why you should build a completely brushless wind turbine.

Welding cable is a highly specialized power transmission medium used for grueling applications that demand extreme resistance to twisting, turning, abrasion and pulling. Welding wire is also exposed to UV rays 10 x more intense than the Sun in welding rooms so it can withstand above normal levels of UV radiation. Welding wire is made using hundreds of very small and soft, ductile strands of annealed copper wire and will last for over 50 years while being subjected to over 2,000,000 cycles of twists, tugs, bends, turns and other torques per year. It is also water tight and the special rubber jacket is especially made to withstand millions of hours of abrasive action.

The professional welders who have used this great cable for over a century drag it over their rough shop floors decade after decade. Many welding machine's used for ship building during WWII are are still in use today and are over 70 years old. Even after 70 years those cables are still going strong with no sign of replacement needed any time soon.

To replace the slip rings in your old wind turbine or to install one of ours you will need two pieces of 6# welding wire, one red and one black. This will go inside the pole tower and can withstand lots of twisting and turning motion.

IF you don't have any obstructions near your turbines to block the wind, then purchase a water pipe as your mounting pole. Choose schedule #40, 1-1/2" water pipe for light wind areas or schedule #80, 1-1/2" if you live in a real windy or storm prone area. This pipe is available at any Plumbing or Hardware type store. I would recommend you have them cut the pipe to 15 feet. This will give you 3 feet cemented into the ground and a nice tall 12 foot tall mast that will not require messy looking guy wires.

But, if you need a taller tower, we sell the tower kits, buy Sch.40 pipe per the spec for the tower kit you buy. The two options are 27' and 45' towers.

But if 12 feet will work, then it is just high enough to easily be worked on with an 10 foot painters ladder and is tall enough so kids can't get cut by the spinning blades. While you are at the hardware store buy a post hole digger and a few bags of premixed "post hole" cement too (Por-Rok, or fast drying concrete). Remember the welding wire is only to hold up to the twisting action of the turbine head in the pole. Welding wire is too expensive for long under ground runs. The longer run of wire can be done with UF type direct burial type wire. 10 gauge 4 conductor is fairly cheap. Double the wires up for maximum amperage. Twist the black and the white together to become the positive and then the green and copper together for the negative. A 250 foot box is about $120.00. You can check with us for current pricing on 10/3 w/ground Type UF. Run this wire under ground as UF type wire is a water proof, direct burial type wire that is easy to install without need for conduit.. Finally connect this wire to your battery with the proper fusing or DC breakers based on your system design.. You are basically done with the hard part. What you do with your battery power is you own prerogative: Grid Feeding via Grid-Tie Inverter, Powering an Inverter, Heating water etc.

*Note: IF you use a pipe over 12 feet tall on a wind turbine that has a 65" or smaller blade diameter it will need guy wires or need to be at least Schedule #80 to resist bending when a storm hits!!! However wind turbines that have a greater than 65" diameter MUST have guys wires AND be mounted with schedule #80 pipe! Our tower kits are safe with Sch.40, see our tower page.

More On "No Slip Rings"
Our advice on slip rings is to use heavy rubber coated welding cable and don't worry about twisted wire. Twisted wires in the pole are an overrated problem in modern small wind turbines. Heavy rubber welding cable tends to simply unwind when it is under tension and the wind turbine head favorers turning in the opposite direction to effect unwinding. Welding cable also has special qualities when it comes to taking continuous twisting and has incredible abrasion resistance when rubbing inside the pipe. Welding cable will last for about 50 years (Not even slip rings will last 50 years)


If you use a terminal block with lugs to connect your welding wire to the UF wire, you need to get a block rated for highly stranded wire, welding wire. Over time, in the wrong block, the wire will loosen up. Regular tightening would be required by the owner but electrical inspectors will soon be strict on using the right block.

In all our testing slip rings eventually failed and required maintenance while over 100 small test turbines equipped with #6 rubber welding cable operated with an exceptional 100% dependability factor for over 14 years now and counting. 100% reliability

Yet more on the - "NO SLIP RINGS" Topic
If you have #6 rubber welding cables and put them in a wind turbine tower pipe you can only turn them about 20 or 30 times in any one direction before they get tight. Interestingly enough this point they react like a giant Rubber-Band and try to turn the other way trying to unwind themselves. A simple rubber tension system was born from welding cable! It's very reliable, cheap and never fails. No moving or rubbing parts to fail. Welding cable is specially made cable designed to endure endless abrasion, twisting, bending and turning motions offering at least half a century of service life or more. Especially if it's in a dark pipe with no UV shining on it. It should last a life time.


Drill a small 1/4 drain hole at the ground level of the pipe. Fill the pipe with a few cups of liquid cement (water mixed with Portland cement powder only, NO sand or rock!!!) When this mixture comes out of your 1/4" drill hole then chase it with a gallon of clear water. If it cogs during pouring use a piece of wire until it flows clear water. DONE! - Water in pipe problem gone!!!!!!!!!!!

Tower strength
We only talk in terms of lateral loading or in simpler term sideways thrust or loading. Your Hawk turbine creates 1200 lbs of lateral loading at 115 MPH.
That is like a car with a rope tied to the top of your tower applying 1200 lbs to the tip of the mast in an attempt to pull it down. Your tower manufacture should understand this.
If you are in a cold area also remember about 'icing" that brings down more towers than just wind alone does. In other words BUILD YOUR TOWERS TOUGH!


Q. How do you get the electricity down from the generator as it changes direction to face the wind? Would the wire get twisted without sliprings?
A. Our turbines do not have a tail that flips to the left or right in high winds so how can the wires get twisted??? This is a 70 year old misconception left over from a bygone era when ALL wind turbines made in the 1930's would turn in one direction for high wind protection. IF you simply use rubber welding wire (made for twisting, abrasion and tension resistance) and tension the welding wire at hard points like a rubber band it will never be able to make enough turns to get twisted before it desperately wants to release it's build up tension energy and literally unwind itself in the pole. Welcome to the the new millennium and evolution from old ideas.
Many wind turbine manufactures brag about their brushless PMA's and also admit to the terrible dependability of carbon brushed generators. Then they do something very puzzling, they install a set of carbon brushes in their slip rings assemblies! Is this not at odds with their own philosophy?

FACTS: Carbon brushes wear out, sooner or later, snap like ice sickles in freezing weather and
those are just a few of the cold hard facts against the use slip rings and carbon brushes in general.