Trouble with spool gun...

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I have one of those cheap lincoln plastic spool guns on a Mig 15 (same thing as SP-175 i believe). Took a little custom wiring to get this gun to work with the welder but that aspect of it all works fine. Trouble im having with is inconsistent wire feed and jamming in the contact tip. Seems to work a little better on the higher settings, still has some problems. But whenever I try to turn it down on C or below its causing even more problems. Seems like replacing the tips helps alot, but i can see them going downhill after like 10 mins of intermittent welding. How long should i expect from a tip?Any advice? This is driving me nuts. I've been able to make some decent welds at times but this inconsistancy isnt helping things at all.
Reply:Murray, what material are you welding, what size and grade wire, and what tips are you using?If you're welding aluminum, you really want to use 5356 filler for a mig gun. 4043 is a good filler, but it is too soft for migging in most instances without a push/pull gun. It can gall up in the drive roller, and you are where you are now....If you are welding aluminum with .035 filler wire, try using a .040 tip instead. Aluminum will have friction and gets a bit sticky in the tip. Also, aluminum wire will swell in the tip once electrically charged. This will cause drag, and then you get to be where you are right now. Also, try to keep the wire stickout a little farther than you would for steel. The arc right at the tip of the gun will burn back to the tip, and then the wire will stick, and ........you're right where you currently are!!If you're welding steel, then there is a problem with the drive wheel tension or something like that!!!And then, after so much work...... you have it in your hand, and you look over to your side...... and the runner has run off. Leaving you holding the prize, wondering when the runner will return.
Reply:Im mostly working with 6061, sometimes some 5000 series marine grade aluminum. I've been using 4043 wire, i have tried the 5356 and wasnt too impressed with the results. Had similer problems with it binding in the tip and the welds didnt look as great. I considered going with a bigger tip too. Wire size is 0.035 inch. I dont have acess to any 0.040 tips locally, maybe i might try drilling some a little oversize. Anything else I can try? Has anybody else used this spool gun? How do you find it? I wondering if some of my trouble is a wimpy motor in the gun.
Reply:The gun does have a little underpowered motor ini it, but the tips are your biggest problem. A tiny drillbit will help, give the wire a little room to slide easily, and you will have less problems.And then, after so much work...... you have it in your hand, and you look over to your side...... and the runner has run off. Leaving you holding the prize, wondering when the runner will return.
Reply:How about some photos of a few of the welds.  May give an indication of one or more possible contributing factors.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!