help with my Lincoln welder

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I have a lincoln weld pak 100 converted to MIG(normally flux core) and has been for quite sometime..It's been a good,reliable machine but now have a problem don't know where to start looking.. The welding wire is shorting out (glows red) where it goes into the drive rollers..Anyone ever heard of such a problem?..I checked the wiring for burned/melted casings and saw nothing bad..  I realize this is a cheap machine,but it is convenient to use and I'd like to get it working if possible..Thanks!
Reply:Did you reverse the polarity on it ?"I'd Rather die on my feet , than live on my knee's"64' Lincoln Sa 200 Redface Code 5496 - Sold 72' Lincoln Idealarc 250 (Roundtop) MillerMatic Vintage
Reply:Where it's red there's current flowing (lots of current).Is this between the drive rollers and the spool?  The rollers should be electrically hot.  If it's between the rollers and the spool, then your spool is shorting out somehow.The polarity won't make much difference,  there's current flowing where current shouldn't be.Dynasty200DX w/coolmate1MM210MM VintageESAB miniarc161ltsLincoln AC225Victor O/A, Smith AW1ACutmaster 81IR 2475N7.5FPRage3Jancy USA1019" SBAEAD-200LE
Reply:Sounds like a bad joint, The welding current is going up the wire instead or the gun cable. I would check under the rubber boot of the mig gun(machine end). make sure the copper cable hasn't been pulled out of the crimp.
Reply:Originally Posted by AndyAWhere it's red there's current flowing (lots of current).Is this between the drive rollers and the spool?  The rollers should be electrically hot.  If it's between the rollers and the spool, then your spool is shorting out somehow.The polarity won't make much difference,  there's current flowing where current shouldn't be.
Reply:Originally Posted by bucketSounds like a bad joint, The welding current is going up the wire instead or the gun cable. I would check under the rubber boot of the mig gun(machine end). make sure the copper cable hasn't been pulled out of the crimp.
Reply:1934ford - Something has happened that has introduced a grounding path on [in] the machine.  This happened to me about 10 yrs. ago with aMiller D60.  This wire-feeder has two guns and will run 60 lbs. reels.I modified one of the arbors to run smaller reels and your problem resulted.  It took me quite a while to find the problem.  In my remodel I had not properly insulated the arbor roller assembly, thus introducinga ground path from the reel [wire frame] to the rollers.  I believe this maybe your problem, but the location of the fault could be some distance removed, so systematically look everywhere.   OPUS
Reply:you didn't have the welder sitting on the job. i.e. the frame or the welder at the same potential as the ground cable? or your ground terminal is down to the frame.
Reply:Originally Posted by bucketSounds like a bad joint, The welding current is going up the wire instead or the gun cable. I would check under the rubber boot of the mig gun(machine end). make sure the copper cable hasn't been pulled out of the crimp.
Reply:Thanks everyone for your replies and insight..  I looked at it today a little closer and noticed that the arbor in which the spool of wire rides on is metal..Then I realized where the ground path is coming from..The roll of wire has a small portion of wire which comes out the hole in the plastic when it is manufactured..Evidently to wind the wire on the plastic spool..The small portion of wire made contact with the metal spool on the machine and fried it to a crisp..  I've never run into this before and I have been welding with this machine for at least 5 yrs..Does this make sense?Is this just a coincidence or should I keep looking for another problem?  I haven't tried insulating the spool of wire from the metal arbor it rides on to see if it still has a problem.. Thanks 34
Reply:you found the problem. The spool should be plastic and no need to add any thing there.But put a paper or thin card board washer between the wire spool and the center panel.The weld current found a path from the work clamp into your electrical system ground.Traveled through it and up the welder's ground wire in the power cord, into the case of the welder to the roll end you saw. completing the circuit and causing the weld wire to turn red and melt. Unplug your welder and remove the case. Check the green ground wire in the line cord and make sure it is not melted. If your cord unplugs. open the plug and check for melting. A melted power cord could short out at any time and cause a problem.