Date:         Tue, 2 Oct 2007 00:52:18 -0600
Reply-To:     "Gary Lee www.vwrack.com" <gary2a@TELUS.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         "Gary Lee www.vwrack.com" <gary2a@TELUS.NET>
Subject:      Re: MIG welding.
Content-Type: text/plain; charset=US-ASCII; delsp=yes; format=flowed

 >What kind of wire welder did you end up getting? I guess a lot of us
 >are looking and brands/numbers are good.

 >In reading up on MIG welders, it seems that regardless of 110 or 220
 >VAC needs, I may have to run a new circuit (20 or 30 amp) from the
 >service panel. I was hoping to get away with a 110 on a standard 15
 >amp breaker, but maybe not.

My welding, I do a lot of it, is all for vanagons.  Here are some of
my opinions, in the context of vanagon usage.
110 volt migs are okay for sticking thin stuff together.  It won't
look good, especially if you are using flux core.  But the machines
are inexpensive to buy and will work.  Don't even think of making
trailer hitches or doing structural repairs with a 110 volt welder.
Not enough heat, not enough penetration.

You will need a 20 amp outlet for your 110 volt mig.  You may be able
to get by with a standard 15 amp circuit for short bursts, but the
breaker will probably be tripping all the time.

When welding, go slowly and smoothly.  Avoid jerky erratic
movements.  With these small migs you have to go slow to get enough
heat into the metal.  The bead will look better if you weave a
consistent pattern.
Use both hands to hold the gun if needed, one hand near the tip.
Again, smooth and consistent will give a better looking bead.  Relax,
don't have a death grip on the gun.

The $60 autodarkening helmets from harbor freight and princess auto
work fine for the infrequent welder.  Put that on your list of things
to buy, it will make welding a lot easier.

If you are using a 110 volt welder, use the thinnest wire you can
get.  That would be .023 for gas and around .030 for flux core.

- Keep the gun cable as straight as possible, this helps with feeding.
- Keep the spool of wire clean.
- Don't bother trying to weld aluminum with any of these cheap (under
$2000) welders.  It's tricky to get it  to feed at the best of times
on a good machine.
- Cut the wire at an angle, this helps starts with small machines.
- If the wire is burning back, increase wire speed.
- Your first attempts at welding sheet metal will be frustrating.
You'll get burn throughs and unwanted build ups requiring grinding.
- After a while you will learn to finesse the trigger to control heat
and burn throughs and to fill gaps.
- A properly set up mig (wire speed and voltage) results in minimal
spatter.
- You will get used to the sound the arc makes to know when the setup
is correct.  Smooth sizzle vs harsh crackle etc.

Properly done, mig welding can be fast, strong and look good.

Gary Lee
Miller XMT 304 power source
Miller 22a wire feeder
Miller dynasty inverter tig
1986 vanagon

www.vwrack.com