Need advice for light aluminum welding

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HelloI have an older Miller M250 mig welder, with a Sg 300 spool gun ratio 1:20. I am trying to weld .120 wall 1x 1 1/2. I use the push method. But i cant seem to find the right setting. The settings on the welder are  Burn Back, Run in speed, wire speed control and there's wire speed control at the bottom of the spool gun also. I have the voltage step selector set at 1. I'm getting alot of splatter and burn holes. Im also using 0.032 wire. Any advice would be appreciated.Thanks
Reply:Any suggestions at all !!   I thought this forum was full of PROS
Reply:Originally Posted by CAJAny suggestions at all !!   I thought this forum was full of PROS
Reply:Now, describe for me how the weld puddle is starting? How does the wire handle the speed/ voltage input? What speed is it you're actually running, and what volts/ and amps are you running with? Usually, a lot od spatter is telling you the wire is either not making a good contact with the puddle, and is not feeding and filling the puddle as you move. OR; the heat is as such that the wire(alum) is melting before it hits the puddle.Need some ppics, and a better description to give you more to work on.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:Get rid of that .032 dia wire.  Must be some off brand stuff from China.Most use .035.Are you trying to use 4043 or 5356 wire?  WFS is different for each.What is your experience with mig welding?Have you ever used the spoolgun before?Now, what are the real settings you're trying to use.We may know what we're doing when it comes to welding but we're sure not "mindreaders".  Help us out here.Last edited by Rojodiablo; 04-03-2010 at 11:50 PM.Reason: saving the world, one post at a time.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:HeyJust trying to find some settings that you guys might yous for light aluminum. On the welder that i am running. Thanks for your time
Reply:Hey Sundown!!!The wire Im useing is 4043 .032 Blueshield crystal. Whats the diff between that and .035,Thanks
Reply:I had the same problem when I first tried a spool gun, just takes practice but my alum. is usually 60 thous.or thicker and usually 035. 4043 for railing pickets ect.Good luck Jim
Reply:The wire speed and run-in speed controls on the welding machine will not be usable when using the spool gun.  You will set the wire speed on the spool gun and the voltage on the welding machine, so those are the only 2 controls you need to concern yourself with.  If you have alot of popping and spattering and have the machine set with the voltage on '1', turn up the voltage setting until you have enough juice to burn off the wire smoothly.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:I think your only feasable option is have someone with a TIG do it for you.....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.