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I'm resurrecting an obsolete MIG welder and you can't buy feed rollers for it anymore.
I'm obviously looking to see what other models/ brands are adaptable, but if push comes to shove, I will consider making a feed roller to suit hard wire, and to suit flux core.
anyone got ideas on how to do the flux core one?
I figure the hard wire is simply a v groove of suitable depth, and the soft wire is a "u" shaped groove of similar depth (say 50% wire diameter)
thanks,
Des
I found the flux core roller for my Millermatic 150 and it had a pattern in the groove. You might be able to find a Miller part that you could use/modify, or get fancy and make a groove with a knurl?
Hi, Des.
looking at my own welder, it reminds me of the knurls that Chris created in this video. perhaps this could work for you?
https://youtu.be/i9pD5vIHJ8M
I used a knurl, Machined a piece of tool steel to a V shaped edge then used a straight knurl to impress a pattern on it, it made a good result on a prepared grove.
Thanks all - I'm looking at my options with modifying a Bossweld part, or using a dental bur (IC) to create the knurl, or the suggestion from tooly. Speed and ease may tilt towards the modification - but I will have a go at making one "for the exercise". working with 0.8 or 0.9mm wire means the groove and knurl will be small.Quote:
Originally Posted by tooly
you could run it against the side of a tap and simply cut a worm around it.
Hi Des, can you tell me what brand & size of the mig welder as I may have some parts from old weldersQuote:
Originally Posted by desbromilow
Thanks Trevor
It's my Dad's old transMIG 190 - the rollers are 30mm in diameter. I found Bossweld offers a range of 30mm rollers which are 19mm wide, and that allows me to put a M5 set screw between the grooves (0.8 and 0.9 mm) to engage on the flat of the shaft.Quote:
Originally Posted by trevor_60_r
The welder came to me broken down with some intermittent faults stopping the wire feed. I found nearly every connection inside was loose, and the pilot relay from the handpiece switch is on it's way out. I think I now have it fixed, so the next step is getting it to feed wire.
Des
A lot of the wire feed motors are 12v or 24v DC which you can test with a car battery. Most of the Mig stuff i have is the separate wirefeed units from 3 phase machines, I do have some spare feed rollers from some of them but not sure what diameter they are. There are heaps of different size and styles of rollers from different manufactures that i have seen in over 47 years as a boilermaker. I will see if I can have a look tomorrow what i have that comes close to the dimensions you have described. Some of the knurled rollers that are used on fluxcore wire are made in 2 halves split at the grove and held together with screws, that would make it a bit easier to knurl each half then clamp together align up the knurls and drill for screw holes. Just some of my thoughts for now.
Thanks Trevor
Trevor,Quote:
Originally Posted by trevor_60_r
Thanks for the suggestion on the split roller - I never thought of that option.
Des; Have you tried to contact Bob the welder in Ballina 02 6681 3393 He may be able to locate them for you or direct you to where you can find them.
Cigweld is an Essab brand this link may direct you
https://www.bing.com/ck/a?!&&p=51933...JvbGxzLw&ntb=1
Anning if it welds for a while and shuts down a few have found the transformer on the PCB had an intermittent short replacing the 12va transformer with a slightly larger Va rated one solved the issue. connecting the machine to a circuit on the mains with a higher amperage rating has helped others. Any of these smaller machines no matter the manufacture does not fare well with voltage drop from line loss. I've had Telwin, Hobart, Miller, Lincoln, and numerous other brand units, that would die because of trying to use them on too long of a small diameter extension cord. Line voltage loss is a huge killer of anything.
Hi Des,
The Bossweld one they make for UniMig would be very close to what you want with some small modification like making a bush to fit in the center of it as the hole is 22mm and wouldn't be hard to make. Would have to make a spacer to fit at the back if needed to get grove to line up. Bossweld and some of other companies make feed rollers for different machines so you may get another one closer to fit.
{UPDATE} Just found this one
This one would be real close
https://www.hampdon.com.au/Gasless-F...30-x-10-x-19mm
It fits the following machines
- Bossweld
- Unimig
- WIA Weldmatic 215
- Weldskill 155 & 185
- Transmig 185 ultra
- Weldskill 250 & 350c
- Weldskill 4R Wire feeder
- Transmig 165ST, 175i & 175i+
- Transmig 200, 225, 255, 275, 350 & 400
- Transmig 215SE & 265SE
- Transmig 320SP, 400SP & 500SP
- Transmig VF4 & VRF4 Wire feeder
- CIG equivelent part # 7977734 (0.8mm)
- Suits WIA W26 Series
Thanks Trevor
You can buy an entire wire feed assembly on AliExpress for like $70.
Also they have a wide variety of rollers, some which may be a direct fit or some others with very large arbor holes which would be ideal if you were to make your own bushing.
https://www.aliexpress.com/w/wholesa...wire-feed.html
Lots of options on there.
Or you can buy an absolutely DIRT cheap spool gun and convert your machine to use that. I've bought a bunch of them. They're far better than they have any business being for $50.
https://www.aliexpress.com/item/33041973384.html
Thanks All... @Trevor - that is the roller I've bought from AIMS industrial (made by Bossweld) - with the 19mm width, I should be able to drop a M5 set screw (grub screw) between the grooves to engage the flat on the drive axle in the transmig - that's the plan for this coming weekend anyway. FWIW I found AIMS industrial was about 30-40% cheaper than anyone else (including shipping) for the parts I bought... Hampdon was next cheapest.
@ Frank - I hadn't tried Bob, but I did have a helpful contact inside CIG tech support who checked their obsolete/ old stock category and he confirmed no availability of the parts I needed. I've read the transformer issue somewhere before, and that is the next thing to replace once my new relay arrives this week.
I did several unloaded tests (pulled the trigger 30 times, saw the relays click in and the wirefeed spindle turn 30 times) and everything looks good now the connections are all tight and remade. I then did a loaded test (burned some wire using the wrong wire for the roller in it) and found for 20 trigger pulls, I got normal operation 18 times, and twice the trigger pull acted as if it was dead - then the next pull and it worked fine.
I've ran conduction tests over the trigger wires and it's passing when I shake/move the handpiece lead.
back to testing without load ( no wire burning), and I'm back to 30 of 30 again.
Assuming the transformer is loading differently when the machine is actually burning wire, I will replace it as a preemptive strike.
@nova-robotics - thanks for the tip on aliexpress - I looked at some of those options before I found the rollers in AIMS - I was quite impressed with some of the options in Aliexpress until I logged in and the moment that happened all the prices changed. Shipping with Ali is often what breaks their appeal for me. (looked at some wingnuts on the weekend - $15 for the wingnuts, $68 for the shipping - compare that to $25 inc shipping locally in Aus)
Why not just buy a set of rollers the appropriate diameter with the grooves you want and modify the mounting holes?