Mig welding aluminum?

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Is it possible to weld aluminum with a miller mig 135 (110v) without spending a fortune for the spoolmate gun and spoolmate 185 controller?I really do not need to weld aluminum - but would like to try working with it. However - if it would cost $700 to get set up - then I'll pass!!Thanks - Mark
Reply:Short answer, YesLong answer, it may not come without significant frustration...You will have to run your MIG at max amps and depending on material thickness, your wire speed near max also.  I doubt your 135 will be able to handle much over .250" thick.You will have to keep the torch cable as straight as possible to avoid feeding problems and "birds nests" at the drive rollers.   I zip tie a length of PVC electrical conduit to the torch cable (on a Lincoln Weld-Pak 155 and Pro-Mig 175) and plan all my welds such that I am working at the full length of the torch cable.  This might mean lengthening your ground clamp cable.Set your drive roller tension loose such that if you block the wire at the torch end, the drive roller will slip.5356 alloy wire will feed a lot better than 4043 alloy, but it may wear through your teflon cable liner.   5356 is also better suited for welding on 6000 series alloy aluminum (assuming the bulk of aluminum you will use will be either 6063-T5 or 6061-T6.Welding aluminum is much different that steel.   You should push the weld, not pull it and pay close attention to the weld puddle.    If it starts to flatten out, it's too hot and you have to either stop or speed up you travel speed.     Once aliminum gets too hot, it's all over.  You'll be looking at a burn through before you can cuss.Again, short answer, yes, but plan for some frustration.  Good Luck.There are no small projects
Reply:Thank you for the reply and advice. As I was saying - I don't really need to weld aluminum but wanted to just try it. I was afraid it would turn out a disaster or even worse - damage my welder. Now - I think I will try it - along with your method. This way I can experiment without taking a 2nd mortgage on the house!! Once again - I really appreciate your help.Thanks - Mark
Reply:I did that with my MM135..just to play around. It worked fine. You will be maxxed out and 1/8 is the best you will do with a sound weld. Thicker will be too cold. I got .030 4043 to run the best. It was not pretty when I ran the 5356. It just doesn't have the goobers to run it.You will need straight argon, no way around that one...and I would suggest the Miller Teflon liner. It made a huge difference. I was getting a big birdnest every two inches with the std liner, and maybe every foot with the teflon. I can't find the part number, but it is the one for the M-25 gun...Miller only makes one liner. It'll fit the M-10, no worries.
Reply:Keep your gun and lead streched out as straight as possible. The more bends in your liner the greater the friction and the more problems you will have.