best idea yet - cut down those long mig cables .

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been getting feeder nests w/ the miller s-60  , and naturally inspecting the guide wheels and such , DUH !  my tweco whips were unnecessarily long and werebinding  , causing misery .               i cut  5 feet off an 18 footer ,  running .035 ,   and 2 feet from a 13 footer ,  w/ .023 . lining .   not a casual repair, but not difficult either .  basically , i took a bolt cutter to the CableHoz , at the machine connection side , removed the wires , plugs, spade connectors for the trigger ,cut  the oetiker band w/ a dremel ,cut the gas hose , prepped the wires ..... then reconnected everything , using a standard , stainless  spiral SS hose clamp to replace the crimpedband . there was plenty of room in the tweco housing for the new clamp.should have been obvious....... works fantastic .Miller S60 feederCobramatic push/pull feederMiller CP-252tsLincoln Tig250/Tig250Lincoln weldpak 100 -italianC-H 90A- italianHarris & Victor O\Afull manual & CNC machine shop
Reply:Good job!I too have less feeding problems with short torches, especially with alum and stainless wire.Weld like a "WELDOR", not a wel-"DERR" MillerDynasty700DX,Dynasty350DX4ea,Dynasty200DX,Li  ncolnSW200-2ea.,MillerMatic350P,MillerMatic200w/spoolgun,MKCobraMig260,Lincoln SP-170T,PlasmaCam/Hypertherm1250,HFProTig2ea,MigMax1ea.
Reply:Originally Posted by tnmgcarbidebeen getting feeder nests w/ the miller s-60  , and naturally inspecting the guide wheels and such , DUH !  my tweco whips were unnecessarily long and werebinding  , causing misery .               i cut  5 feet off an 18 footer ,  running .035 ,   and 2 feet from a 13 footer ,  w/ .023 . lining .   not a casual repair, but not difficult either .  basically , i took a bolt cutter to the CableHoz , at the machine connection side , removed the wires , plugs, spade connectors for the trigger ,cut  the oetiker band w/ a dremel ,cut the gas hose , prepped the wires ..... then reconnected everything , using a standard , stainless  spiral SS hose clamp to replace the crimpedband . there was plenty of room in the tweco housing for the new clamp.should have been obvious....... works fantastic .
Reply:Using a clean and proper size liner with no kinks and the correct drive wheel tension works wonders too.Drive wheel tension should be adjusted so as NOT to create a birds nest but still be tight enough to push the wire through a clean liner with no kinks without slipping.Glad it worked out for you but just sayin'.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Originally Posted by duaneb55Using a clean and proper size liner with no kinks and the correct drive wheel tension works wonders too.Drive wheel tension should be adjusted so as NOT to create a birds nest but still be tight enough to push the wire through a clean liner with no kinks without slipping.Glad it worked out for you but just sayin'.
Reply:That was my original problem with my first welder - the HF Dual Mig 151. The wire feed would just bind and stall the motor. It didn't have a steel liner; it had a plastic tube. I stuck it in a corner of the garage and forgot about it for over a decade (got a Lincoln Pro-Mig 140 to replace it - works great!).I'm in the middle of doing all the mods described in the thread over in the HF sub-forum here... we'll see how it behaves with a proper reasonably sized steel lined torch on it.
Reply:I've seen worn our inlet and outlet wire guides create feeding issues also. Results in pinching the wire.JasonLincoln Idealarc 250 stick/tigThermal Dynamics Cutmaster 52Miller Bobcat 250Torchmate CNC tableThermal Arc Hefty 2Ironworkers Local 720