Can you all help me hook up my TIG ?

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It has been a very long time since I used a TIG  and at the  time I remember it was orange.  So it wasn't the one I have now.  Because what I have now a blue Miller TIG unit - but I have no idea how to arrange it to play nice with the only welder I have left.  Which is an A/C-D/C Lincoln tombstone.An old friend of mine wants me to build him an aluminum bike frame.Let me go see if I can find you a model number - OK:   Miller HF 251D-1  But it looks like there is no torch or external control for it here.   Think it can be made to work?Or can I stick weld aluminum?
Reply:it will work but you will have no amp control on ac so you travel speed is going to be what is going to make it work not very easy for a beginner all the miller unit is going to give you is HF startMiller Xmt 350Lincoln Ln-25Ahp 200xSmith Gas Mixer AR/HTig is my Kung FuThrowing down dimes and weaving aboutInstagram http://instagram.com/[email protected]
Reply:Here is a photo of how it hooks up.I also have the manual on PDF if  you would like it emailed to you.Hookup instruction label should be on the inside of the side cover as mine is.Basically, you hook the torch cable to the power/gas connector and then attach it to the lug marked "Electrode Out".You connect your welding lead from the welder output, to the lug marked "Electrode In".  To weld aluminum you would use the A/C outputs from the welder to the HF251D-1. Either connector works as electrode or work connection lead for A/C welding.  One to the "Electrode In" and one to the "Work Input/Output" lug.  Your ground clamp also connects to this same "Work Input/Output" lug.  They are bolted down together on that one lug.  Also, for aluminum, set your HF251D-1 switches to "Panel" for the control type and "Continuous" for the High Frequency setting.  You will need a torch body with a manual gas valve or you would have to run gas constantly with no shut off except at the regulator.To setup to weld on steel you would connect the negative output from the welder to the "Electrode In" to get DCEN polarity.  Torch connects to "Electrode Out" using the gas through cable power connector (brass thing).Positive connector from welder hooks to the "Work Input/Output" lug.  This is  your "ground" or "work" connection.  The positive lead from the welder hooks to this lug along with the ground cable together on same lug.Argon gas hose from  your gas cylinder/flow meter connects to the flow relay solenoid input. Short gas hose from the solenoid connects to the torch cable power connector.Your HF251D-1 unit would be set to "Panel" for control and "Start" for high frequency setting which will give you arc start only.  You have to have a tig torch fingertip control switch in order to use the "Remote" setting which gives you HF "On/Off" control and gas post flow capability.Last edited by MWalden; 08-06-2013 at 01:49 AM.
Reply:Couple of problems here my friend.Real world, it's the setup I had at one point.  It's nearly impossible to weld aluminum well with.  No arc control.  Even if you add a pedal, you will be able to start the arc only.  You can not adjust the amps and when you come off the pedal, the AC arc will sometimes not extinguish-even with the HF off.Second is welding an aluminum bike frame.  Sounds like you've been out of practice for a while.  Tigging thin walled aluminum tubing is no easy task.  Plus, the areas that you weld will be weaker than the parent material unless you heat treat and harden the entire frame after the welding is complete.Thirdly, I'd be glad to send you a few aluminum stick rods for free, you pay shipping.  They're pretty much useless unless you need to weld really thick stock or it's an emergency.   I'd love to see someone weld tubing with some.  Pretty much a hot (really hot) mess with burn through and white milky flux everywhere.I applaud your courage and efforts for this project, but it's fraught with issues.  You will likely be wasting alot of time and money and not be thrilled with the results.TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum