Wire jambed in the TWECO Weldskill #2!

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Hello all! I'm a old guy, my first 100% certs were in 1966. So now I mess around in my son's offroad shop here in AZ. My current challenge is with the older Miller 35 equipped with an older TWECO Weldskill #2 gun. Currently set up with .035 wire. Too often the wire jambs at the drive wheels. Last time I disassembled it at the 'rear case' where the cable, conduit and such join. I found the wire to be 'sticky' when trying to feed it through. Just twisted it a bit and it freed up! So I put it back together....it worked well for several days and jambed up yesterday! Frustrating as there's good ground new tip and nice straight lead.  Any one had this happen and can share a fix? Thanks, Jay
Reply:That is a fairly old machine that could have a lot of use.  My initial thought would be to pull the gun liner to inspect to see if it is bent or kinked.  If not then maybe the liner has been clogged.  Some welders say to blow the liner out with air but I have found that smaller diameter liners don’t play so well with blowing air through them.  Is the liner inside diameter correct for the wire size you are feeding through it?  Those were suppose to be really good auto body panel machines hence it may be set up with a smaller diameter gun liner.  The liner should have markings or a tag to indicate a part number which can be used to cross reference a new liner if needed as well as to determine the max diameter of wire that will work with the liner.Last edited by N2 Welding; 06-03-2021 at 08:54 PM.Lincoln, ESAB, Thermal Dynamics, Victor, Miller, Dewalt, Makita, Kalamzoo.  Hand tools, power tools, welding and cutting tools.
Reply:It sounds like your MM35 was converted to a newer gun style in the past.  The original Miller gun had a large shroud covering the gas line, power lead and liner and the gas valve was in the torch.  They stopped selling parts for them many years ago so most folks converted the machines to use a different gun.  The problem with that is we can't see what setup you have.  With some of the conversions you have to add pieces of liner to the front and back of the wire feed assembly to keep the wire lined up as it gets to the drive wheel and as it gets to the start of the gun liner.  If those are missing, or the gaps are too big you'll get feed issues and frequent jams.  Post a picture of the inside of the machine showing the wire feed setup and we might be able to help more.Check out my bench vise website:  http://mivise.comMiller Syncrowave 250DXMillermatic 350P with XR AlumaProMiller Regency 200 with 22A feeder and Spoolmatic 3Hobart Champion EliteEverlast PowerTig 210EXT
Reply:Ah yes, the liner pieces are there! The placement of the liner pieces is critical, they need to be very close to the drive wheels. I'm headed to the shop this AM. i'll try and post photos. Thank you!
Reply:Do you have photos of problem. I would check the liner size and the wire size. Dave

Originally Posted by Hammer Mechanic

Hello all! I'm a old guy, my first 100% certs were in 1966. So now I mess around in my son's offroad shop here in AZ. My current challenge is with the older Miller 35 equipped with an older TWECO Weldskill #2 gun. Currently set up with .035 wire. Too often the wire jambs at the drive wheels. Last time I disassembled it at the 'rear case' where the cable, conduit and such join. I found the wire to be 'sticky' when trying to feed it through. Just twisted it a bit and it freed up! So I put it back together....it worked well for several days and jambed up yesterday! Frustrating as there's good ground new tip and nice straight lead.  Any one had this happen and can share a fix? Thanks, Jay
Reply:Drive wheels could be worn or set too tight causing copper to flake off the wire and plug the liner. Have also seen bad Mig wire that is wavy in sections or intertwined on the spool. Could check tension on the wire spool too. I'd probably get a new .035/.045 liner (and contact tip) and make sure it is cut properly so it mates with the diffuser and contact tip correctly. Liner should be tight to the diffuser when gun is coiled some. Have seen people install a new liner with gun straight but put a slight curve in the gun and the liner has gap at the diffuser.
Reply:wondering what ever happened with this?Lincoln, ESAB, Thermal Dynamics, Victor, Miller, Dewalt, Makita, Kalamzoo.  Hand tools, power tools, welding and cutting tools.