Finally got time to work on this. The split bolt idea worked great. Thanks for your help and ideas.

I got the split bolts and No-ox-id. Do I put the no-ox-id on the wires FIRST and then clamp them in the split bolt or clamp them first and grease over the connection?

I like the split bolt idea. I'll assume they can handle the amps well? I've never used them so I don't know what they're capable of.

I've had a Miller Thunderbolt 225 AC/DC for 20 years and done lots of little stuff with it. I use DC only and have never removed the leads from the machine. I decided to get new and longer leads to make things a bit easier. The push in ends to the machine have evidently corroded or got stuck as I co...