Airco Dip-Pak 200 w/Tweeco gun - feed problems

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I've got this old Airco - has been a workhorse, but now I'm right in the middle of a project, and it has let me down! This machine actually belongs to my son, but he's up in the cold country, working the oil fields, so I kinda inherited til he gets back.  This thing has always had a little erratic action on the wire feed, he kept telling me it was dirty wire, so bought a new spool.  Not much difference.  He then suggested liner problems, so replaced it and tips etc.  Not much better.  Yesterday, it welded pretty good at the start of the day, after an hour or so, kinda slowed down. When I say an hour, probably welded for 15 mins.  This morning, got my parts all laid out and clamped in place, and it just will not feed wire. Cleaned the drive wheels with carb clnr, cleaned and lubed the wire spool axle and brake, replaced the tip. I've got the tension on the wire spool as loose as I can get it w/o unrolling. It'll try to feed, but after a few inches, the drive wheels slip. I can grasp the wire with my fingers, and with very little pull, it feeds.  As I pull the wire, it feels smooth. Upper drive spool is smooth. Lower is grooved for .035 & .045.  There is no adjustment for wheel tension, merely pinches the wire between the flat roller and the groove.  I have the lower drive roll and a piece of wire here in front of me.  The wire looks good, copper looks intact, shiny etc.  If I wrap the .035 wire around the spool in the .035 groove, appears to me that it does not stand proud of the groove.  I'm assuming the drive spool is worn out, although every thing I read seems to say they don't wear out.  I'd buy a new one and try it, but can't find one. Any suggestions?
Reply:You say there is no adjustment on the drive rolls? There must be unless the spring was removed. You got a picture?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:If I'm thinking correctly, the .035" groove will be on the opposite side than it is actually stamped ".035" on.      I know I've made that mistake before .      doh !L-Tec PCM-VPi II Hobart Handler140Millermatic 35Lincoln Power arc 4000Lincoln Ranger 10,000 ( 3 ) Longevity Tigweld 160SX Purox O/A setup100lb anvilXLO/servosource cnc mill
Reply:Call ESAB tech support at (843)-669-4411 Ask if there are any drive rolls left. Have all the information about you welder handy. Serial number , stock number and ect.ESAB bought the Airco equipment division.
Reply:If you can throw up some clear pics with measurements others can see what might fit. Pics of the feeder mechanism too.If you have a friend with a lathe they could skim a few thou off in minutes if in fact the groove is an issue.
Reply:I just noticed that the markings on the drive roll are .035R & .045R.  Does that mean anything?  On this old Airco. the top roller is hinged, and is held down on to the bottom roller by a flat spring that swings over and goes under a clip.  There is no adjustment. There's an old timer over in town that has a small welding business building barbecues etc.  He's been welding for about a hundred years.  I'm gonna take the feed roll and a few feet of wire over and let him look at it and see what he thinks. Next stop is the Paxair dealer in Palatka.  He's also Esab dlr, he said bring him the roller and he'd try to match it up.  When I get back, if it's warmed up, I'll see if I can get some pix.  It's 31 this morning, and the shop isn't heated, and that's way to cold for an old man in Florida.  How far should the wire stand proud of the groove?
Reply:The main thing to look for. Put a short piece of wire (about 1 foot) in the drive and set the pressure roll. Grab the wire with your fingers and pull. If the wire pulls out easy and the rolls do not move, the rolls are worn out. If it is hard to pull out and the rolls move with the wire they are ok. The roll you have works with two sizes of wire. If a twin groove roll, the smaller groove is for .035 wire and the larger is for .045 wire. Trying to drive .035 in the .045 groove will not work well.Check the flat spring pressure arm. make sure the mounting screw is tight and the hook is tight.Check the hook it might be adjustable and loose.As suggested, If you can't get a roll. Cutting 0.001 off the roll Might help. Putting a shim between the arm and roll assembly may help also. Just figure out what works best for you.
Reply:Originally Posted by ccawgcThe main thing to look for. Put a short piece of wire (about 1 foot) in the drive and set the pressure roll. Grab the wire with your fingers and pull. If the wire pulls out easy and the rolls do not move, the rolls are worn out. If it is hard to pull out and the rolls move with the wire they are ok. The roll you have works with two sizes of wire. If a twin groove roll, the smaller groove is for .035 wire and the larger is for .045 wire. Trying to drive .035 in the .045 groove will not work well.Check the flat spring pressure arm. make sure the mounting screw is tight and the hook is tight.Check the hook it might be adjustable and loose.As suggested, If you can't get a roll. Cutting 0.001 off the roll Might help. Putting a shim between the arm and roll assembly may help also. Just figure out what works best for you.