Ugly Aluminum Welds!

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I have just started trying out a Spoolmate 100 gun with my Miller 211MVP. I am using 110VAC, .035 wire with 100% Argon. I am attempting to build an alum cart to hold my welder and tank with a snap-on side box mounted below. I am using alum box 1/8" wall 1.5" square. The frame will be box butted 90 degrees to box. I have cleaned, power brushed (stainless) so it is nice and shiny. So I clamp everything down, ground the work and try laying a weld. Looks like crap. Try it again with same results. The I try an angle pce clamped fimly to the box, try welding it and voila, looks great. Is it possible that because the 2 pcs of box are not firmly clamped together that it is possibly a ground issue? Any other ideas would be much appreciated. Attached Images
Reply:Just a guess since I have yet to use a spool gun (I will next week) but are you on the correct polarity?And sure the aluminum isn't anodized?Torchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:Not sure what your doing but i've welded ally before and its hard to get a nice bead especially on box sectionYou just need to practice, Try and weld flat as oppose to going dowards or going uphill
Reply:Polarity is fine. Material seems to have no film or anodizing. This is my first time trying it so I wasn't looking for a miracle. However, using er4043 wire welding a pce of box and angle together firmly clamped had good results. This was photo 3 on original post. Attached Images
Reply:Now thats what I was hoping to get in results, well somewhere close would be cool.
Reply:If the aluminum is anodized, would it be obvious to the eye? I have only known it to have color.Alan SimMillerMatic 211 MVPHypertherm Plasma CutterSpoolmate 100Stronghands Welding TableLots of plans, Eager to LearnBeer in ice boxStereo rockin'Hot neighbor!  Update...married her!
Reply:Originally Posted by Gerry1964Not sure what your doing but i've welded ally before and its hard to get a nice bead especially on box sectionYou just need to practice, Try and weld flat as oppose to going dowards or going uphill
Reply:They are sweet. Is a spoolgun gun capable of welds close to yours?Alan SimMillerMatic 211 MVPHypertherm Plasma CutterSpoolmate 100Stronghands Welding TableLots of plans, Eager to LearnBeer in ice boxStereo rockin'Hot neighbor!  Update...married her!
Reply:Look up weldingtipsandtricks.com and find his post on using spool guns on aluminum.  Very helpful.  I tried his suggestions and they worked well.  However, I prefer TIG on aluminum and that's what I use instead.Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:Originally Posted by hvpguyThey are sweet. Is a spoolgun gun capable of welds close to yours?
Reply:Originally Posted by hvpguyThey are sweet. Is a spoolgun gun capable of welds close to yours?
Reply:I have the same machine and spoolgun.  With the spoolgun using aluminum you MUST PUSH, NO PULLING and ensure the ground is on a cleaned portion of the work piece not just clamped on the table.Everlast PowerPro 256, Everlast W300 Cooler, Everlast Cart 250Millermatic 211, Spoolgun 100, Miller HD CartJackson W60 Truesight Digital Auto Darkening, Victor 315 Torch sitting on a Harper 830-86 cart
Reply:too thick of material for 110v. put down the power wire wheel. use a toothbrush style stainless brush for new aluminum.Dynasty 200DXPassport plus w/ spoolmate 100victor 315c oxy/(act and prop)Miller digital elitemilwaukee power tools
Reply:When I did 1/8” aluminum angle I didn’t have any issues running .035 4043 on 115 VAC.  The rod holder came out good.  I even had enough “heat” for some 1/4” T joints on the 1/8”. Attached ImagesLast edited by Grandslam99; 01-13-2013 at 03:32 PM.Everlast PowerPro 256, Everlast W300 Cooler, Everlast Cart 250Millermatic 211, Spoolgun 100, Miller HD CartJackson W60 Truesight Digital Auto Darkening, Victor 315 Torch sitting on a Harper 830-86 cart
Reply:Is the spoolgun meant to be used with a 110V machine? I experimented years ago and couldn't get enough heat even on thinner sections, although I see other posts with others that have the same package.
Reply:Originally Posted by blackbartIs the spoolgun meant to be used with a 110V machine? I experimented years ago and couldn't get enough heat even on thinner sections, although I see other posts with others that have the same package.
Reply:Grandslam99, I really like your rod holder great idea.Sent from my iPad using Tapatalk HD