short clip how to get you started welding aluminum
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Thanks for the tips
Thanks for the video! I found a couple of things that I was doing wrong, starting with the tension on the spool. When you said "every time that happens it costs you a couple of bucks"…..ding, ding, ding!!! That hit home!
A buddy of mind has a miller spool gun and he try setting it for aluminum .He tried to weld aluminum. But just gets splatter and will not even weld bead. his power supply is an industry miller mig welding machine. He also took in to have it check out,but they too could not figure out the problem. Any Suggestions?
Does anyone know if you can rig up-wire an aluminum spool gun up to a harbor freight 170 amp mig welder?
Check your polarity ! Just like fluxcore welding , work clamp is positive ! Sometimes we forget the little things ! I've done it before ! Should clean up your welds ! Clean the aluminum too ! Happy welding !
good job on this video
Will this work with a Lincoln weld pak 140?
This has knurled drive rolls why?
What about when the spool gun has a flex neck does the tension knob still control that
Great video! I'm just starting to weld aluminum and I really appreciate the pointers. For the camera while welding, maybe set up an auto darkening helmet in front of it? I've seen some videos of guys using helmets in front of their cameras but its tough to follow, an auto darkening helmet would allow you to show the set up as well as the weld. You could also play with the settings to get a nice filter for the camera.
Thanks for your video I just got this setup and I always like to learn what I can before I mess things up..
I work with this same type gun, it can be very temperamental and at times frustrating. But I think I have ironed out all the kinks in the gun. In the shop I work at we have a very old ( I think this gun had been in the shop for 20 yrs) miller spool gun running on a 250 miller. we use 035 wire and I run ALOT of aluminum so ive gotten some great results. It runs great on 1/8 but you have to run real fast and ittakes some getting used to. I set my Machine on 21 amps and wire speed at 4. Some spools of wire act a bit differently, not enough where a novice will notice, but when you have a lot of spools under your belt you will feel it. When it feels like it is slowing down, turn your wire speed up just a small amount until your spool runs out, then turn it back to 4. Common problems and fixes. the biggest and the most time consuming problem that Ive ran into is the wire will burn back into the tip. When a burn back occurs, and you try to push the trigger again to see if that will free the wire,(never do this unless you want to waste a bunch of tips) what happens is the aluminum wire is soft and hot, this causes it to push into the tip and jamming up into it. Once that happens you may as well get a new tip.The fix is to take about 5 tips and drill out the inside just a little to about .045. When drilling your tips use a lot of water based cutting fluid so that your drill bit does not get over heated and twist off inside your tip. You can also clean your tips like this when they become plugged up. As I mentioned before I drill 5 tips at a time and this way I don't have to stop long I can just replace the tip and continue working, then when time allows I re drill the tips Ive plugged up. make sure you use a lot of anti splatter spray when inserting a new tip in your gun. Keep your tips clean and free of spatter while welding. Don't be afraid of using the anti spatter spray, it will help keep your tips working longer In this video I saw that you was using your tensioner and adjusting it. I NEVER USE MINE. Aluminum will not birds nest like steel, so I leave mine off.(and yes I twist my gun to all kinds of angles and I've never had an issue with mine)
Next Issue after twisting and turning your gun all over the place, the power cable will eventually become disconnected from all the use(its going to happen eventually) dont worry its an easy fix. 1. turn off your machine and unplug it, and turn off your gas for safetylay your gun flat on a clean surface. Using a star screw driver start to loosen up the screws. Once completed remove the screws and make sure not to loose them. (NOTE there is a spring located at the trigger, when removing the housing this spring will pop out and if you are not careful you will lose it. I take a clean rag and place it over the housing so that when it pops out, it has no where to go but inside the rag.) 2. remove the piece where the wire has broken off and heat it with a propane heater to remove the old wire and solder, clean it really well and set aside. cut the power cable, and trim the rubber coating back that just enough wire will insert back into the adapter. Using flux, coat the cable really well. Place the wire back into the adapter and solder the 2 together.allow to cool. 3 place the spring in the proper place, replace the housing (this may take a bit to realign it properly) and replace the screws and tighten. Plug in the machine, turn on the gas, and you are ready to weld again. You can also replace the trigger this way also, it is fully enclosed so that all you do is disconnect the 2 wires, replace with new trigger and reconnect the wires. (REMEMBER THAT THE SPRING WILL FLY OUT WHEN TAKING IT APART) Yes it has happened to me and it took me forever to find it
To prevent this from happening again I am using a zip tie to hold up the cable and keep it from twisting all over. I drilled 2 small holes into the spool housing at bottom and ran the zip tie into the housing and around the cable and gas lines. If the holes are drilled into the middle of the housing you should not have any problems with the spool being interfered with. I would recommend if your gun did not come with one, that you buy a Kevlar sleeve to protect your cable and gas line. It runs the full length from machine to gun and will protect it from burns, dragging across the ground, and general use.
I have been welding for over 20 yrs and did have some training back in welding trade school. Till about a yr ago I didn't have much experience with welding aluminum. It took me a full day to get used to running differently than what I was used to. But once you see the way aluminum works and behaves, it can be fun to work with. Aluminum heats up really fast and will melt quickly, especially with thinner material. Move fast, adjust your gun angle because of the wire curving from the tip. If using thicker material remember to run 1 pass and allow it to cool or pour water on your piece, then run your next pass.
Well this is about all I can think of at the moment, if you have any questions please feel free to email me at firstname.lastname@example.org I would be happy to answer any questions. I am even thinking of making my first video
Personally I'd go with the PowerMTS
I picked up an Everlast spoolgun which is very similar to the Spoolmate 200. If the Miller is built the same, it is very rugged. If you get the heavy duty barrel it will do 60% duty cycle at 200A.
Is this spoolgun by miller pretty durable and reliable? I plan on building a aluminum boat next winter and been researching the hell out of both the Miller 30A and the MK Prince XL spoolgun. The prince is more money but so much more lighter it seems.
@Mark Stevansen are you picking up the PowerIMIG or PowerMTS MIG welder?
Thanks for the tips. I'm getting pretty close to pulling the trigger (pardon the pun) on an Everlast MIG welder with one of their spool guns (very similar to Miller spool guns). Your tips will come in handy.
Good video, I got the Hobart Iron man 230, whit the spool gun, work great, pay $1800 . Im trying to weld stanley steel whit the spool gun, any comments?
that was for the whole setup
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