I am sick of this! (mig feed problem)

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O.k. I am just sick of this. I have spent the last 3 years trying to figure out my wire feed problem and I still haven't. It always starts out fine, smooth feed, even. Then after awhile it starts to get spitty, starts to be uneven, fits and starts. It no longer makes the pretty and perfect line it starts with.

This is what I have done to no avail:

Changed liner. (helped for awhile)
Changed tips. (helped for awhile)
Changed clamp. (helped for awhile)
Made sure all connections were solid, no loose areas that jam up the current as the welder gets hotter over time. (helped for awhile)
Tried different clamp locations. (helped for awhile)
Anti-spatter on the tip. (helped for awhile)
Changing the settings as the welder heats up. (nyet)

What the *@!#%@! am I missing? I would be done with my work in half the time if this wasn't happening.

I cannot remember a workday without a feed issue.

I so far have beat up my gun and my studio door today. That doesn't help so much.

I am hoping someone can clue me in. Pleeeaaasssee!

Thank you,
Alex


Gene Olson's picture

why ya spit

I can see you have started.

Have you tried Duct tape yet?

Vi a duct?

Alex,
We missed you at the shindig.

On your welda, trying to find other things . . .

How about the drive rolls. How is the tension there, are they slipping.

Gene Olson
Sculptor
Elk River, MN


SteelyJan's picture

Try This????

Hi Alex,
I bought a 110 mini mig to bring on jobs when I have to weld on site....all it did was drive me crazy!!!!!! It seemed that I didn't know how to weld. Very embarrassing when your on a job and your welder is spitting and jumping and being obnoxious! I brought it in to my local welding supply store and we figured out the gun connection wasn't tight enough. It was only slightly out at the inside connection. The tiny loss of gas was making the whole big deal. Try evrything and then bring it in for a check up. Good Luck Janet


Frank Castiglione's picture

(**&^%$#@ing MIG

Hi Alex,
Here's a few things I do beside cursing. I polish the outer lens with scotchbright. Then I regularly clean this by removing crud with a fat rat-tail file avoiding the copper with the file but catching the crud with the file teeth, its quick and dirty.I use a cleaning device that rides the wire just past the drive wheels.If you have the machine cranked up to the max, watch out that you don't get the gun too close to the work.I use an OA torch cleaner quite frequently on the tip and grind any ferrous crap off the tip and bevel the tip end some.Try to keep any tight turns out of the guns line.Use the thickest wire your machine will take. Take a hammer and beat the living shit out of a piece of metal. Weld several of these together and sell the pure emotion. Works fer me!
Peace,eh?
Frank


Rick Crawford's picture

welding problems

Maybe you just got a bad roll of wire? I would try another roll, and if it acts the same, then I am not sure what to try next. (sorry, but I think you have tried about everything else I know about.)

Are you able to weld for a while ok, or not at all?

Maybe Valerie Rock will poke her head in here and help some. She seems to know WAY more than me.

good luck,
Rick Crawford at Smoky Forge


PeterG's picture

Alex I have had a similar

Alex

I have had a similar problem before. It really drove me nuts. I had a tantrum one day and broke the end off the handpiece. After replacing it the problems ceased..... I guess sometimes losing your cool pays off.

Another problem I've found is rust on the feed wire. Just a small amout of rust on the wire builds up inside the liner over time causing jamming. If your welder sits in damp, humid areas, that could be an issue.

The only other suggestion I have is to clean up the wire drive mechanism. I assume you have tightened it to the point that the wire turns spagetti before it enters the liner.

Good Luck

PS If nothing works, replace the whole cable/handpiece. You will live longer and die happier.

Peter


visitor's picture

Alex, You don't say what

Alex,

You don't say what kind of welder you have. It would really help to know that, as different machines have different issues. I've had a couple of Lincoln units that gave me fits and I finally switched to a Miller that has been flawless. The only time it ever quit feeding was yesterday, and I had simply run out of wire. That was easy!

Tell me what machine you have what wire you're running, what gas, etc, and maybe i can offer some ideas. Without that info, it is only guesswork and generic answers.


Ries's picture

I, too, suspect the problem

I, too, suspect the problem is you just have a cheap, worn out machine.
Tell us brand and model.

I betcha its 110volt- and until recently, those machines just never worked very well.
Plus, Lincoln, among others, was famous for selling a "discount" version at big box stores, with "improved" features like plastic drive wheels, no bearings, and many other cut corners.

A good new machine might be the answer.


Alex in Welderland's picture

Yes, I think it is time...

Thanks everyone for the wonderful answers. I think I have to admit that it is time to go shopping. I used to have a big ol' 220 but had to downgrade to be able to work in a studio I was in.

It actually is a 110 Lincoln, bought from a big box store, (whose name I will not mention, because it always makes my skin crawl).

Um, now that I think about it, I am a bit self-conscious to admit that the machine is 12 years old, and, um, yes, I think it may be time...

Thanks again for all your help.

Alex

p.s Miller or Lincoln?

************
www.custompeturns.com
"a special place for a special pet"


Rich Waugh's picture

Miller. Definitely, Miller.

Miller. Definitely, Miller. I have had Llincoln, Miller and Airco, and Miller is the best. With one caveat: if your local dealer is only a LIncoln man, then get a Lincoln since he's the guy you're going to have to go to for parts and problems. But if you have a choice, get the Miller. And get the 220v machine. The 110 volt machines are for hobbyists, unless you get into the high-end inverter units.

Remember: At the end of the day, nobody says, "Hey, it's Lincoln time."


Bill Roberts's picture

FWIW I'm partial to Miller

FWIW
I'm partial to Miller TOO. :)
Dos Centavos


Alex in Welderland's picture

Yes, I think it might be Miller time

I am going to give it a go. Switching to the blue...

Alex
************
www.custompeturns.com
"a special place for a special pet"


jbin's picture

Definitely Miller

Hi Alex,

I have one of those old Lincoln mini MIG units and it was never a stellar performer.
I am in love with my Miller Trailblazer, it is the nicest welder I have ever used.

Jim


Gene Olson's picture

lincoln

My small 220V lincoln wirefeed seems to be holding up just fine. Was that the 110 version?

Gene Olson
Sculptor
Elk River, MN


Alex in Welderland's picture

Yep

It is the 110. I need to save up some cashola for a new one. But I am looking forward to trying the blue!

Alex
************
www.custompeturns.com
"a special place for a special pet"


Frank Castiglione's picture

Good Choice

Hi Alex,
Good choice on deciding to buy a BLUE welder. If you would have chosen to purchase a RED welder I could, with a clear conscience, have congratulated you on that decision too. Both companies make a fine product, and the obvious rivalry between the two is a driving force behind the competitive pricing and constant evolution of their products.Pressure from some fine YELLOW machines sure doesn't hurt.I have a Lincoln 220V MIG, its over seven years old and I recently made over 250 small welds, at the highest setting,in the course of three hours. It never flinched.I wouldn't hesitate to buy a Miller though. That depends on the price and available service more than brand loyalty.
Peace,eh?
Frank


J.R. Tamayo's picture

Millermatic

Hey Alex, how ya doin

Dancer was made with a Millermatic 140 (110V). For the stuff you're making, it's power enough. I love my Miller.

J.R.


Gene Olson's picture

Power, yes,

Power, yes,
but stamina
that depends entirely on how much is done continuously.

DUTY CYCLE ratings are low on the 110 machines.

Ya gotta remember, that is only iron, wire, and fire
and we are talking about Alex here.
She's a
WOMAN
Double you
OOOOOOOOOOOOH - em aye en
let me tell you again . . . .
W - O - M - A - N

(with thanks to Kweskin and the band)

Gene Olson
Sculptor
Elk River, MN


visitor's picture

If I only had 110 volt,

If I only had 110 volt, which until late last year I did, I would get a Hobart Handler 140. I have this unit and have run at least 10 11 pound rolls in it. One issue, I lost the spring and nut on the feed wheel. When I replaced it, no more problems.

It is a USA made machine that is made very similar to the Miller.

Just my humble .02


visitor's picture

MILLER OR LICOLN

I'M A BIG FAN OF THE BLUE MACHINE. HAVE BOTH STICK AND MIG. LOVE THEM LIKE MY WIFE. ALWAYS DEPENDABLE.


Canaday Designs's picture

Personaly I dont care what

Personaly I dont care what the color is
but
I've had a lincon 255, hated it
Just got rid of a miller 210, hated it
My buddy has a miller 250, we both hate it
i've got a miller pasport (inverter, goes 110 or 220), love it
and I have my trusty lincoln 200, love it, actually this is my second one the first was stolen (i could have shot someone that day)
oh ya and ive had and used numerouse 110v welders, only thing there good for is pissing you off
good luck Alex,
Matt


Alex in Welderland's picture

I am saving my pennies

I think I might have to have a few more go-rounds with my old welder, but hopefully soon...

Alex
************
www.custompeturns.com
"a special place for a special pet"


Glen Jones's picture

Wore feed problems

Hi Alex,
Before you give up on the old red girl check the shaft that the spool sits on is not to worn.
I teach apprenticce classes of 13 students who are all welding at the same time and I have noticed this has been a hiden problem on old machines.

Cheers
Glen


Glen Jones's picture

wire feed problem

I dont know how I ended up on this page a year old but I did. So Alex do you still have the old MIg machine or did you trade it in?

Cheers
Glen


Nathan Logsdon's picture

hey Alex- cannot tell you

hey Alex- cannot tell you how wonderful the miller passport is. 110 or 220- on board co2 for site work. Mine is over three years old and even though I had a problem with a faulty switch once it was fixed this machine just rocks! Contact your miller rep and get a shop demo- you will never go back.


moose's picture

Another thingto look at is

Another thingto look at is how much wire is left on the spool. I have had issues with feed when the wire is getting low on the spool having a hard time coming off. I cure it by "SLIGHTLY" looseningthe retainer nut for the spool. Allows it to turn easier.

Tim
metalcraft by moose
Art to Automobiles


man of mettle's picture

lincoln works fine

i've had a lincoln mig for four years. works great. as for your problem - i would say it has to do with the tension. or perhaps the wire is in the wrong slot.

keith


Stephen Fitz-Gerald's picture

Lincoln 110

Stephen Fitz-Gerald
I was given a Lincoln 110 by a ferrier friend who was disgusted with it. I rigged it for flux core to be used for onsite work which I RARELY do but once in a while HAVE to.I was working with it out in my yard welding some trellises to my "Pendentive Gazebo"when it started acting up with the same symptoms you described.I looked in the box to adjust the tensioned and to my disgust saw that the whole drive component was made of PLASTIC ,and it had just simply fallen apart in about 10 pieces . the plastic was brittle and crumbling like it had been exposed to too much UV and deteriorated.! I couldn't believe it.I took it to my local welding supply in high anxiety mode until they told me the replacement module was only 25 bucks...I got the new unit in 2 days ,installed it and it works fine. It IS a piece of poorly designed junk,but at least the parts were cheap...
What I use in the studio is a MILLERMATIC 250 (for steel and bronze)and a MILLER 175(for stainless steel).


visitor's picture

MIG

Hi Alex,
Everyone has had very good thoughts on your problem, but it does sound like you are ready for a new welder. I've been welding for about 25 years now and have seen a lot a new advancements over the years. I think no matter which brand you choose these days a new machine is going to work great. I am partial to Miller machinces but also use Hobart and a big old dinosaur Lincoln wire feeder at work and it still works good. I understand your frustration with the issues on your machine, cause nothing is worse than having problems with your equipment when you are trying to get things done! There are very good quality 110V welders out there from all three brands if thats what you need. Anyway good luck and let us know what you get.

Aloha, Wade


visitor's picture

welder not working right

check the drive wheels to make sure they are set at .023
,030 or .o35 or whatever gauge you are trying to weld .on smaller welders you can turn the drive wheel around for various thickness wire


visitor's picture

problems welding with a 110 machine

Some of the problems discussed here are very common. I have been welding for 35 and have experienced all the above mentioned problems. First off if the machine is foreign made your going to have problems I learned a long time ago if it's not a Lincoln or a Miller you won't see it in my shop. I have tried the cheaper brands with no luck. Another common problem is the power source a 11 machine needs to have a good power source or it will NOT work correctly if you are using an extension cord your creating the problem. The further away from the breaker you are the weaker the amperage and these machines are very sensitive. Also try adjusting the wire speed more so that the power and you'll see an improvement. I currently own 2 millers and a lincoln and like them all.
Steve