Welding Question

[tubbyfirefighter]

I just purchased a speed way 125w flux core welder. my question is why does it pop and throw splatter everywhere when i weld? also the wire feed is intermitten and does not come out continously, is something broken or wore out? I bought it used for 50 bucks so i cant really complain. any help will be appreciated.

[Diz Jr.]

So many things it could be.

With these smaller welders you really have to keep the lead with the gun on it pretty straight. If you get very much of a bend in it can cause it to feed irradiclly. Are the feed rolls tight enough? Is it just spining and not feeding the wire. Is it to tight, to tight can cause problems too. It will acctually flatten the wire as it is feeding it and can cause trouble. are you sure you have flux core wire? It pops and cracks more than solid wire with shielding gas. But it still should run smoothly. Do you have the right size tip for the wire you are using? Again to small or to big will cause problems.

I am assumeing you have tried turning the wire speed up and down a little to see if you could smooth it out a little. Is the wire really old or rusty? This is just the first few things that come to mind. Some one else my have some other ideas. Let us know if this helps.

[JMD]

perhaps it has the wrong wire intallled sounds like no flux.

[zelda]

My welder has different feed rollers for different wire size. Flip them around.You might want to check that. I agree with all the above . . .

[MikeC]

There are several; variables. First is the surface you are welding ground down to bare metal. Rust, even little specs of it are notorious for causing "rice krispies." (snap, crackle, pop) as in grounding an electrical circuit ( which is esectially what you are doing) cleanliness is the key.
Make sure you have the right type of wire(flux core)
The distance from the tip to the surface, as well as the power lever, if adjustable is also a possible cause.
As for the intermittent feed, along with keeping sharp turns out of the feed tube, you should check on the tension wheel. Most of the small welders have a small know above the bock where the wire goes into the hose. Tightening it down a bit will often improve the feed.
When all is adjusted properly you should hear a buzz as you weld.
Hence the name applied to these smaller welders - "Buzz Box"
Mike C.

[tubbyfirefighter]

Checked the wire and after a back lash attack found it to be .035 flux core wire. took off the drive roll and it has two grooves, on smooth and one not, it was set up for the smooth side, switched it and added a little wd40 and took apart the gun and cleaned the nozzle, spring ect and shes welding like new! now if i can sneak over to the mother in laws, she wont be able to open her car doors in the morning!! Thanks for all your guys help

[green 4 acres]

sounds like weak welding first you need to be able to melt the steel turn it to high and see how thick of steel you can melt I own a 120 and a 151 harbor frieght mig welders my advise replace the ground cable with bigger american cable and a strong clamp almost a two hander that fixed mine . most try to much wire feed set it at 1 mine wont go slow enough with the large wire spool and best to preheat the weld with a propane torch hope this helps Don