Amperage too high for welding thin metal

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I have an older Miller Dialarc 250. I have a tig torch that I have used  with this welder that has worked well. When I want to tig weld thin metal, the lowest amperage setting is still too high. My question is, is there a way to lower my lowest amperage setting which would allow me to weld the thinner metal without having to purchase another welder?
Reply:Hello and welcome. I'll move this to the Mig, tig, stick area so it gets more views for you and you can get more replies.It would help if we had more details. What thickness of material, what are the minimum amps you can run down to and what are you set at. Picts? I ask because we need some place to start and many times it's basic issues that guys generally assume are correct that aren't listed that turn out to be the problem in the end.Assuming your material is in the range the machine is capable of, it might be a machine issue vs a weld problem. There are a few things like how far away you hold the tungsten and how big the filler is, plus your travel speed that allow you to do some things to control how hot the machine welds at a given setting, but that only gives you a small amount of control in the down direction vs turning the machine down..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:How thin is the steel you want to weld? I just checked google images, looks like 35 amps is about the lowest on some of the machines. With some practice you should be able to weld some thin stuff with that. Do you have a foot pedal with the machine? Does the amperage adjustment on the machine work?Airco Ac/Dc 300 HeliwelderMillerMatic 200 (stolen)Miller Maxstar 150STLMiller AEAD200LE (welding and generating power) Hobart MIG
Reply:I assume you have the dial arc 250 and not the dial arc HF. The 250 has a high / low range and the HF has hi/med/low range switch. The low end of the 250 is around 40 amps. the HF gets down to around 10. About all you can do is get some ni-chrome wire or flat strap. Just needs to be large enough to handle the lowest current your machine puts out. Put it in series with the work lead. The longer the wire the lower the amps you will have. Ni-chrome wire is resistance wire used in electrical heaters. You can tare junk heaters apart to get some for use and tests.Once you figure out what works, you can measure the resistance  with a high quality volt-ohm meter. Then you can build a expanded metal  box and figure out a way to make it a little adjustable. Or a higher wattage so it lasts longer. may glow orange and get real hot.another way is an old fashion salt water rheostat. Uses a bucket, two carbon electrodes and a salt water electrolyte. The more salt used the more current gets through.
Reply:Thank you for the info. I was wondering about some kind of resistor, you have given me some ideas to expierment with. You are right, my lowest setting is 38 amps. Thanks again.       Ron
Reply:Thanks for the reply. My lowest setting is 38 amps and yes my amp adjustment works. I would like to weld 18 gage metal. This welder seems to run a little hot even when stick welding. ccawqc mentioned some type of resistor which is a idea I was wondering about.
Reply:Originally Posted by ront120rThanks for the reply. My lowest setting is 38 amps and yes my amp adjustment works. I would like to weld 18 gage metal. This welder seems to run a little hot even when stick welding. ccawqc mentioned some type of resistor which is a idea I was wondering about.