dang-banged @#^&%$## welding wire

[jniolon]

So I'm starting to hook up my new toy the Millermatic 200

got the gas plumbed -- two welders from on tank... pics will follow someday

wiring done and a new Miller M25 torch in place... I remove the nozzle and tip and feed the wire thru the guides and into the tube... I adjust the tension on the wire feed motor till it will pull wire smoothly and it feeds thru the tube toward the torch... after the wire comes out I slide the tip over the wire and screw it into the torch and reattach the nozzle. try the wire feed again and the wire jams at the mouth of the torch (the welder end)... dang-bang @%$$%^&*$ wire ... take it all apart.. cut out the bad.. pull out the wire and start over... picture this about a thousand times...

I can't seem to find a setting on the wire tension that will keep this from happening and I swear it only happens with the tip in place... it's a .035 tip and .035 wire but the wore feels 'tight' in the tip... it slides but there is the slightest bit of friction... is that normal... I don't feel it in my Hobart Handler tip in a Tweco gun... any suggestions.. ???

I will add that this is an old 44# spool of wire ... discolored but I reeled off the rusty wire... would this make a difference also ???

help oh GMAW gurus !!!!!!

john

[Hobart Expert Rock]

JNIOLIN..........OK..........ZIP THE NEXT SIZE TIP ON THERE........ HOWEVER THE DRAG YOU SHOULD HARDLY FEEL THRU THE TIP.......SO THE DISCOLERATION IS PERHAPS OXIDATION.........YOUR GETTING CLOSER.............THIS ISN'T ALUMINUM WIRE IS IT......................?...........HANG IN THERE DON'T GIVE UP YET..........WE'LL GET YOU THRU THIS..................ROCK
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[Scott V]

Maybe for a test use a larger tip,and see if the samethings happen?

[Bob]

If you don't have .040 tips handy and do have small numbered drill bits:
.035 is a #65
.040 is a #60
You could try opening up a .035 tip with a drill.

Bob

[Sberry]

I think I might get a new roll of wire and see if that works. If it does pitch the old one. For the cost it isnt worth dirtying the new liner up.

[cope]

Not a bad idea to toss the wire. I held onto a partial spool of old .035 that had been left unprotected for years and finally bought a new spool. I could not believe how much better the clean wire welds.

[Guest]

Not only the rust may be a factor, but you may have gotten the wire wrapped under when you reeled off the rusty stuff. Make sure the wire is coming off the spool smoothly.

[jniolon]

dang-banged wire cure

thanks to all that replied...

tried a new roll of .035... shiny stuff and .035 tip....it works like a charm... this welder has lots more umph than my little plastic suitcase Hobart.... I be likin' it

once again... you guys saved my bacon

'appreciate it...

john

[cope]

John, that's exactly how I felt after buying a new roll. Mine wasn't too corroded, just not shiny. I was too stingy to buy a roll. I wont make that mistake again and I don't think you will either.