Baling Wire

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The old Sam.................I hate wire feedersThe new Sam............The redesigned vorral panels are 100% 14ga tubing.  Lghter.  Around 135lbs each.For the first time since I bought it ages ago (Hobart 135, that tells you how old it is) I've been forced to use the thing for something other than tacking sheet metal.  This has been the first 10lb spool run thru the crazy thing.Flat butt welds have given me a HUGE  headache.  I'm used to pulling the stick towards me to fill flats.  Problem with the wire feed is that it's such a small dim arc that I couldn't see crap.  Kept losing the joint line.  After trying everything but standing on my head, I tried dragging from left right and peering under the gun.  While the flat welds aren't as consistent as they should be, they are definitely better.  BUT I STILL LOSE THE LINE ONCE IN A WHILE.  Old eyes maybe?  It's just a PITA to see what you're doingThe fillets are better, visibility wise.  The vertical piece of steel reflects the light and all seems well.Slag removal is a breeze compared to stick. Quick swipe with the cup brush, and it's gone.  Hangs up a bit at the toes, but it is a teeny weenie little weld, hard to get the wire brush into the corners.I really like the ability to make really small tight beads.  Less wasted filler OK, I SAID ITShort repetitive welds are a lot simpler.  No restrike problems like with stick, just squeeze and go.I still have some consistency problems, but it seems to be working out with time and changes in technique.I still feel more comfortable with stick, and wire will by no means replace stick for most of what I do, but this wire thing is pretty cool.Oh yeah, the wire doesn't stand up as well to high wind.  The upwind side of the welds, where the wind was blowing across the weld, show some porosity.  I guess the filler just cools too fast, or is susceptable to wind cooling due to the small puddle  The puny slag may have something to do with it too.  DunnoNow for the GOOD BAD, AND THE UGLYFirst.............Some fillets Attached Images"Any day above ground is a good day"http://www.farmersamm.com/
Reply:And a few flat butt welds to show the problem I have following the joint line  I want new eyes for XMasCheck out the porosity on the upwind side(Pic Two).  Seems that when the wind starts gusting over around 15 you better hang it up for the day. Attached Images"Any day above ground is a good day"http://www.farmersamm.com/
Reply:Looks like the wind did chill things out in a place or two. The look pretty good overall. You can sell that stick outfit after about a week of practice with wire.
Reply:Samm if you were closer, I'd let you play with my VS suitcase feeder on your engine drive. I bet after running .035/.045 FC wire thru it you might just want to ditch the stick thing. All the things that you liked about that little machine, but with way more balls. Some of us will drag you kicking and screaming over to the dark side yet...No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Glad to see  you're having fun with the little machine!MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:Well as you know and will continue to find, every process has its place.Now on to plasma cutters and TIG!!!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!
Reply:Looks like you are getting it, Sam. You should have let us school you more with wire when we had the chance. But, you seem to be doing pretty well  by yourself. To me, it sounds like you need an AD hood. Better optical quality goes a loooong way.QamuIs Heg qaq law' lorvIs yInqaq puS
Reply:The porosity might not necessarily be from wind, with self-shielded sometimes to short of a stickout will cause porosity as well.  With the short stickout the wire doesnt heat up enough to properly degass the flux and you won't get all your shielding elements coming out of it.Have we all gone mad?
Reply:Looks okay to me cept for the undercut.  For those tough to see welds, try laying a piece of flatbar along side it as a reference guide while you weld.Common sense in an uncommon degree is what the world calls wisdom.
Reply:Sam,Were you welding with the shielding gas nozzle still installed on the gun?ESAB Migmaster 250 Hobart Ironman 230Multimatic 215TWECO Fabricator 181i & 211iHH125EZ - nice little fluxcore only unitMaxstar 150 STH - very nice