Converting from .035 flux cored to .025 solid.

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Okay I just converted my weld-pak 100 over to use gas (25- 75 mixture). I'm using .025 solid wire and its welding but now I have more sparks flying than every, it seems I've lost that ablitiy to get that nice sssssssss going when drawing a bead. How can I tell if I'm getting gas or what should my welds now look like(less sparking?) I guess I was expecting alot less sparking and more easying going pools when creating a bead. Anyone have any suggestions on how to check to see if I'm getting the gas mixture to come through the line?
Reply:What type of nozzle are you using?  On my sp135 plus i started out with flux core wire and when i swiched to 75/25 i was using a flux core nozzle and it wasnt getting enough gas because the opening wasnt as big enoughThe first attached picture is a mig nozzle and the second attached picture is a flux core nozzleI hope this helps Aaron Attached Images
Reply:I got the right nozzel, what I just found out was the gas regulator was ****. Sorry but I'm pissed about this. I'm trying to upload a pic so you can see it. But basically that was the problem. I had no open or close valve. Let me post a pic and you will see what I'm talking about.
Reply:Hey,While we're waiting and waiting for those pics of the problem!!!    Here's a site good for a quick visit. With gas and solid wire you won't get quite the same sound you do with flux. Get ready for a different tune. At this site go down to the "short circuiting" link and listen to the audio. With gas, if you're getting a good hisssss and frying you're probably running either too close or too hot. And I do both a LOT.    Don't forget to set the polarity right for your switchover to solid. Pics, need pics!!!Just kidding.  OOOPS, forgot the link.http://www.weldingengineer.com/1mig.htm
Reply:hey thats the website I sent you cool. What I found out is the regulator is bad and I could not get any gas shield to the wire  . I'm trying to upload the pics and see if the person I bought it from on ebay will get me a new one. I would just buy one but they run any where from 35 to 70 bucks.   , Well lets check out those pics. Man It always is somthing..... Oh I listened to that MP3 and that is definetly NOT what my sounded like.  oooh well..   Last edited by satexasuser; 07-31-2005 at 10:49 PM.
Reply:On those regs, on the flow side, there's that set screw that adjusts the flow. Actually it adjusts the low pressure but for us it relates to flow and cfm. You probably messed with that tho. Most folks know as much about them as I do anyway. Set it to 22 to 15 cfm. It would probably cost as much to get it rebuilt as you paid for it. The ebay guy should make it good. Remember now, there is a solenoid valve inside the machine that cuts the flow through when you squeeze the trigger. You should hear that click. You won't get that sound you listened to on the link untill you get the gas flowing. Up till then it'll be quite the concert of spluttering, splattering and crackling with all kinds of bubbles and volcano looking craters forming right before your eyes.
Reply:Sorry my machine is acting up, I don't see any screws I can set, but did see on top of the gauge "listed compressed gas regulator 650L max inlet 3000 PSI". I hope I can put a pick of this regulator soon.
Reply:Actually it normally high pressure gauge on the right facing the reg and low pressure n the left with and adjustment in the center of the regulator. So I should have said adjustment in the center for the gauge on the left. Sorry about that. Some will be a big fancy knob, some will be a 't' bolt, some will be as simple as a 1/4" screw looking affair with a set nut. That will be the flow adjustment. Put the reg on the tank, open the tank all the way open as inert gases and safe gases are backstop valves and made to be opened tight. The while the machine is triggered and flowing adjust the knob/screw for 15 to 20 cfh. Make sure you have the voltage wire speed turned down so you don't pump out a bunch of energized wire there.  The solenoid will still operate with those two down. You should get a whisper of flow out the end of the gun through the holes in the diffuser and carried to the weld by the nozzle. You can barely feel it but should hear it.. BUT, BUT don't stick it up to your ear and squeeze ljust for safety sake. If you ever forget to turn the wire feed off you've just shot yourself in the ear with sharp wire.  You have to release gas through the hose to adjust properly. If it is set high it won't go back down till some gas flows. Make sure your solenoid or whatever arrangement is allowing gas to flow. Step one, gas should flow without the hose hooked to the machine. No danger cuzz it's mostly inert. Watch me on the flow settings. I have a habit of saying cfM but it should always be cfH. Cubic feet per Hour.
Reply:The regulator I have is got  the 1/4 nut in the center with a guage on the left and right and the connector to the tank in the back and the fitting for the hose just below the 1/4 inch nut. What I did first was to hook it all up and then weld or should I say fry bacon(eeeewww). Then I realized I was not getting any gas and started back from the container to check I had gas(yes). Then connected the hose and regulator turned it the tank valve open and nothing. So I took of the hose and opened and closed that center 1/4 inch nut with the tank valve opned and nothing. So then I used another regulater and with the tank valve open again got a good strong ssssshhhhhh out of her. On the new regulator that is bad on the 1/4 inch center nut no matter which way I turned it I never got that ssssshhhh sound to work. So I've contacted the guy who sold it to me and we will see what happens. I can't wait to get this gas flowing withe .025 wire. Oh I took this saturday of from my project to lay some tile for my sister. It was a nice break even though I wanted to do some welding(family first). But today was bit of a struggle since I could not get that regulator to work. I must be getting close to the finish, because every time I get close to the end of a project all these little things start happenin.   Oh on the boots thing, I own 3 pair of shooes my ropers,running shoes and my sandals. In south texas if the snakes were not so big I would hunt in those if I could.. Last edited by satexasuser; 08-01-2005 at 01:00 AM.
Reply:On the new regulator that is bad on the 1/4 inch center nut no matter which way I turned it I never got that ssssshhhh sound to work.
Reply:just for tonight, my buddy is going to lend me his and I'm going to do some practice welds tonight. I'm going to weld in my flooring patch slowly, a spot weld there a full bead there. and then get here ready for paint and off to the shop. I really bit of more than I could chew on this one but I have been accused of being a bit of a loud mouth a times. Oh well.  Off to be, got to go and write some code tommorrow.Thanks
Reply:On a slightly related topic... when you guys are done welding and turn the gas off and let the gas in line out through the gun, do you normally undo the wire feed mechanism, or just turn the speed down, and cut off the wire that comes out while you're letting the gas come through?
Reply:The feeder that I use has a purge button that allow you to release the gas but you should be able to just turn the machine off and hold down the trigger to purge. I never purge unless changing types of gas for example changing from 75%argon / 25% c02 to 100% argon. Satexas if you are getting no gas at all with hard wire the your weld should be full of pin holes to be more exact honeycombed. Is this what you are seeing a pin hole pattern that reminds you of a honeycomb within you weld? when you hold down the trigger you can not hear any gas sound from the nozzle? post your auction item number so we can see the regulator if the auction has pics.Last edited by Robby T.; 08-02-2005 at 12:32 AM.
Reply:you can try removing you regulator from the machine and hooked up only to your gas line turn on the cylinder or "tank" does the regulator expel gas? if so its good if not there is a restriction and may need to replace it.
Reply:The problem was with the gas regulator. In the cener of th gauge there should have been some type of screw of bit to control the flow, there was a place there for a screw, but the whole was not drilled alll the way through so I my friend lent me his and we got the gas flowing just fine. I welded some lines yesterday, but there seem to still be sparking occuring when making those welds. The welds are flatter and the pool is easier to follow but for some reason there is a more sparking (like sparklers) than before. I'm not sure whats happening? With Gas or solid wire should I still have some sparking going on?