Ken:
If your caliper is as big as I'm estimating, and your'e using @ 20 amps, you'll need a good heavy gauge wire. At LEAST 12 ga., and it will need to make good contact with the caliper.
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Is it better to fully emerse the part wire in the electrolyte or have it connect to a wire that connects to the part? It seemed to plate better with the clip directly in the electrolyte.
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It shouldn't make any difference to plating, as long as the connections are tight. I have my clips outside the electrolyte, but as long as they're clean metal, they should work inside the electrolyte as well. They'll simply get plated with the part, and you'd have to rinse them well afterwards.
The problem is, unless the wire insulation is 100% sealed, electrolyte will wick up inside the stranded conductor. You'll never be able to rinse it out, and the wire will soon corrode and fail.
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Something happened last night when I tried to add some top up water to the bath: when I poured the dist water in the bath, it "gelled" up. It was weird. Almost like egg on the top of soup.
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That's definitely not normal. I add water every so often to make up for evaporation, and have never had that happen. Always blends right in.
Have you asked Caswell tech support?
Sean