Need some help with 30+year old welder please

[Wade1969]

This was my Dad’s welder and was last used about 15 years ago. I cleaned it up and replaced the tip. I bought a spool of flux wire but the welder is setup for a big spool.
I have the manual but it doesn’t say anything about using small spools.
I don’t think I can find parts for this so I am thinking I will have to make something.
The tensioner is missing the spring and the face plate. I also need to fix the clamp plug.

Suggestions on how to use the small spool and possibly find replacement parts?

Serial # Jh156116
Stock # 902973-01-4

Thanks
Wade

 

[whateg01]

I don't know how much money you want to spend. When you say big school of wire I thought you meant 30 lb spool versus the 10 lb. But it looks like this is a 110 volt welder so when you say small you must mean the little bitty ones that you have mounted in the picture. That's usually about as good as it gets except maybe adding a spring to keep tension on it. As far as the gun goes it doesn't appear to be all the way in the machine in the picture since there's an o-ring showing. I don't know if you can find nozzles for it or not but you might see if it uses a common type of gun. If you can verify that, you may be able to find an inexpensive yes welder replacement on amazon.

 

[Beerhippie]

All the wire spool needs is enough drag on it to prevent it from over-spooling. A light compression spring and a couple of washers will work just fine--that's what I do when I put 10lb spools in my old Millermatic.

As what^ recommends above, replace the gun and lines with one that you can easily find parts for. None of the wires look good, and I'll bet the liner is pretty well shot, too.

 

[Wade1969]

Thanks guys! Any recommendation on where to look for the gun hose and cable? The hose for the gun is dry rotted.

 

[Beerhippie]

This would be a good time to establish an account with your local welding supply co. You'll be able to get parts, consumables, wire, and gasses through them--including a new gun and hose. If you can, get a hose with PTFE liner as that gives you more options as to the kinds of wire you can use--aluminum, stainless, etc.

 

[whateg01]

Thanks guys! Any recommendation on where to look for the gun hose and cable? The hose for the gun is dry rotted.

Without seeing the whole thing, I doubt anybody here knows which gun it uses. If I had to guess, I would say it's a tweco, but that's just a guess.

 

[Beerhippie]

While you're at it, take a critical look at your ground clamp, cable and plug. With the wear on the gun and hose, it's likely in poor shape, too. I buy the parts and make my own, but that isn't necessarily cheaper--I just get to choose my parts, especially the clamp.

 

[welder4956]

Does the manual give a part number for the gun? May be able to cross reference to a replacement gun.

Edit: Your machine looks similar to a Miller Sidekick mig machine. See if this looks like your gun: https://weldingdirect.com/millerga16c.html

 

[dnschmidt]

To me this looks like a waste of money. Call Primeweld, buy a MIG180 and move on with life. By the time you rebuild this dog you'll be just as deeply in the hole.

 

[2oolhound]

I'm a green horn pretty much but I like dnschmidt's idea of buying something that's already working. It's all those little parts that cost big money when buying new. I PAID $40 FOR MY MIG (SIMILAR TO YOURS) BUT WORKING. i'VE HAD IT FOR ABOUT 5 YEARS NOW (****, hit the caps lock). My $40 mig is still going strong and I just buy wire and tips.

 

[Jswain]

You could remove the mig gun and take pics / measurements of the brass connector. If it is a miller or Lincoln style you can get one on amazon for probably $50.

As for the wire tensioner, like said basically anything will do. Just have to give it enough tension so it doesn't unspool. If you have a 3d printer or a friend it's even easier.

The electrical connector for the gun definitely looks like miller style. Would be wise to try and see if it functions with the current setup if possible but with Amazon's return policy there is basically no risk trying.

Post more pics

 

[Wade1969]

Thanks all! I will look at the parts manual and see if I can cross reference the gun.
To be clear the welder works fine. I don’t do much welding but do have a need from time to time. It was setup for using gas. Flux wire is all I need for the things I would need it for.

This was my Dad’s so I want to keep it and use it as long as I can.

Wade

 

[Jswain]

Sometimes it's nice fixing things.

 

[finn]

HTP used to be pretty good at providing gun assemblies and parts for mig welders other than their own, at a reasonable price. I don’t know if the new owners continued with that service.

It may pay to send them an email with photos, or even give them a phone call.

 

[Jswain]

And if you're just running flux core, it really just needs to guide the wire & provide contact. So if you can't find a torch buy a cheap torch cover & use it for another 30 years.

 

[Wade1969]

Hey guys here is an update. I got a new gun from Amazon and it fit perfect but I am still having an issue with the wire feed.
After about 3 or 4 pulls of the trigger while welding the wire is kinking right after the tension wheel.
I have played with the tension wheel adjustment and the wire speed but nothing helps.

I am using .030 flux from HF. Should I try a thicker wire or is it because I am using cheap wire?

bought the cheap stuff since I am learning but right now I am just wasting material!

Suggestions please.

Thanks
Wade

 

[welder4956]

A photo would help. Usually a kink after the drive rollers is due to too much gap between the rollers and the gun adapter/liner. If it is adjustable, try to insert the gun adapter as close to the rollers as possible, but not touching.

 

[Beerhippie]

It sounds like cheap wire to me, but I've never used flux core. With solid wire, 0.030, I don't have the problem when using mild steel wire, but I do if I try stainless.

Try to keep the hose as straight as possible when welding--it really makes a difference. Then look into getting a PTFE liner for you hose--that also makes a huge difference--chances are, your cheap gun/hose combo has a pretty crappy liner. Pretty cheap and easy to install.

 

[Jswain]

What size are your drive rolls on the welder? Are they knurled?

I would try .035 Lincoln fluxcored wire if the rollers are compatible. Sometimes you need to flip them around. Also what size liner and tip are you running in the gun

 

[dnschmidt]

Flux core requires knurled drive wheels. Check for these first. Smooth wheels are used for MIG and knurled wheels for flux core as it's too soft to drive with smooth wheels.

 

[Joemctag]

To me this looks like a waste of money. Call Primeweld, buy a MIG180 and move on with life. By the time you rebuild this dog you'll be just as deeply in the hole.

180 is $550 on Amazon. I’m going to get one myself.