Settings for Handler 120

[willy13]

Hi!

After buying an aluminum welding kit for my handler 120 12 years ago, I am finally giving it a try. I am running .035 wire and 100% argon gas. I converted to a nylon liner and a rubber feed roller. I am looking for initial settings so I am atleast in the ball park. The setting on the door seem off because it recommends a 1/4" stickout and from what I read you would want a 3/4" stickout. Anyways does anyone weld aluminum with this machine and can offer an initial setting for welding 1/8" aluminum?

Also, does the Argon gas go bad? I have had it sitting im my basement for 12 years.

Thanks,
William

[Fireman]

Hey, im not sure a lot of people tackle aluminum with the smaller 120 but 1/8" might be possible. Ive never heard of a rubber feed wheel so i suppose you are using your regular mig gun. If so im not sure how well it will feed the soft aluminum wire but i do know you will have to keep the hose behind the gun as straight as you can. I would try the highest settings to start with, wire feed on the highest number and the voltage on the highest number. If you are using good clean aluminum and brush it with a dedicated (for aluminum) stainless steel wire brush and don't go thicker than 1/8" you might just do ok. The feeding through the long mig gun/line is my worry for you. The argon will be fine. You will need around 20cfh -25cfh on the regulator when trigger is pulled at least that's been my experience with 1/8". Hope any of this helps and i am sure someone on here has tried this with the 120 and can be more help than me.

[willy13]

Thanks for the info!

I tried some welding tonight and it looks like I am not getting enough penetration especially when I start the bead. The settings are turned all the way up. If I turn the wire feed speed down it begins to burn back into the nozzel. So I am assuming the wire speed needs to be that high unless my stickout is all wrong. I am trying to maintain a 3/4" stickout but not to sure how well I am doing with that. I am thinking I might need to preheat with a torch. Is propane hot enough? Though it certainly could be my technique since I have only welded steel in the past.

I can weld 1/4" steel with this machine so I really expect 1/8" aluminum to work. I won't give up yet!

The wire so far is actually feeding very well. The teflon liner and rubber feed roller seem to be doing there job.

William

[Fireman]

Make sure you are pushing not dragging and yes preheat with a propane torch will help a lot. When your spit boils you know your at least 212 deg. Good luck.

[willy13]

yes, preheating did help, I am now getting penetration. I am pushing not pulling. Now I need to practice...

[Fireman]

Sounds good. Don't forget to make sure the aluminum is clean. I use rubbing alcohol and most use acetone. Your wire brush should be used just for aluminum so its not contaminated. Good luck.