Setting up MIG Welder from scratch

[VL1500]

Hi folks,

Can anyone point me in the direction of some kind of advice for setting up a MIG Welder from scratch? I've found some really good stuff (including Video clips) on how to actually MIG weld different metal thicknesses and joints etc., including power settings, wire speed and so on. But I can't find anything about connecting the gas cylinder to the welder, gauges to the cylinder (do you PTF tape the threads?) or anything else about putting all the separate bits together. It seems that all tuition articles I can find assume that a MIG Welder set-up arrives all ready for use! I bought a "Portamig 180" a year or so back and through circumstances am only just getting to set it up (?) and use it. It was new and arrived in a sturdy crate with the other bits that are needed (twin gauges, Euro gun, pipes & cables etc.) obviously all packed in separate packages. I have a full sized Gas cylinder (Cougar) to use with it. If some kind soul can suggest a source of set-up info. I would be extremely grateful!

Thanks (with fingers crossed)

Tony.

 

[gordon stephenson]

Hello Tony and welcome,
Don't know your mechanical experience or aptitude so answering could be a bit difficult at this stage, But PTFE tape not required as the main regulator fittings have domed or tapered metal to metal faces, Also do not use any oil or grease etc on the threads, this could be dangerous in some cases particularly OXYGEN. I know you have cougar but the OXY warning is just for future reference, There are quite a few members in your neck of the woods, maybe one of them will offer to come and show you how the assembly goes.
Good luck.

 

[boydy1989]

my regulator came with a good little sheet that told you all about plumbing it up, was good. If you really want I will dig it out and scan if for you? Was a good reference for the order of switching on the gas, and checking for leaks etc.

It also said in no uncertain terms DO NOT OIL any part of the gas system, gauges, fittings, etc.

No PTFE tape is needed either, as gordon has said above.

 

[VL1500]

Hi, 'smee agen!

Much obliged Gordon, and thanks for the warnings!

Boydy, appreciate the offer of a copy of instructions. Before you go to the trouble I'll undo the packages again and double check that I didn't miss some instructions in with the regulator or gauges.

Thanks again,

Tony.

 

[Sphinx]

Hi Tony

I had this when I got my welder; it was a hand-me-down from my uncle in bits and I had no idea how/if it worked.
If you have a look in my profile and browse through my first few posts they may shed some light on things.
As for the PTFE, I went through the same thing as I couldn't get it to seal properly even after lightly sanding the connection nice and smooth. I wouldn't want to go against more experienced members advice but a couple of people told me it wasn't the end of the world to use a little bit of tape, so I did and it's worked fine ever since.

 

[VL1500]

Hello Sphinx,

just went back and had a sort through your earlier posts, makes interesting reading! Fortunately I've been Arc welding for years, so I'm OK with how welding works and what joints (butt, lap etc.) to use. It's just that unlike Arc welding where you shove a stick in it and start crackling, there's about 9 million bits of stuff you've got to join together! And the thought of connecting something up wrongly with a bloody great 5ft. metal bomb sitting beside me inspires a wee bit of caution in what I join to where!!
Anyway, if I'm still in one piece after trying to connect everything I'll post whatever the results are.

Cheers,

Tony.

 

[SwissTony]

Cant be a huge amount to it.
Torch plugs in on the front, then on the same connector is a collar which screws onto the welder to stop the plug coming out.

Gas you have already sorted, just 1 tube from the welder to the small outlet on the regulator.

Install the wire making sure to line up the tube in the wire reel with the pin on the portamig spool holder.


Slacken of the tension adjuster on the wire feed assembly (bit with 3,4,5 markings in the pic below) then pull it towards you, now you can lift the top roller, ready to install the wire. Depending on the thickness of the wire, you need to reverse the drive roller so that the correct groove is in the right position.
Undo the wire on the reel you installed, cut of the twisted end so that you have a straight piece of wire to work with, then thread it through the metal tube into the wire feed assembly, over the drive roller and then into the brass tube by a couple of inches. The wire should sit in the groove in the drive roller.

Pull the tension roller down, then flip the tension adjuster up and tighten it up a couple of turns.

Turn the gas off before you do this so you dont waste it.
Remove the shroud and contact tip of the front of the torch, turn the machine on and hold the trigger down on the torch, check to see that the wire is feeding and not making a birds nest in the wire feed rollers
(to aid initially installing the wire, its best to keep the torch lead as straightish as possible)

Once the wire makes it out the end of the torch, slide the contact tip down over it, screw it on, then put the shroud on.

You will need to adjust the wire feed tensioner so that if you try to stop the wire coming out the end of the torch, the rollers will spin but no wire will be fed. Its a fine adjustment, start with the rollers being able to feed the wire with you trying to stop it, the slacken it of until it just starts to slip.

Think thats about it, you already know about wire speed and power e.t.c.

 

[Country Joe]

And when you cut off that twisted end, be sure to keep hold of the other end of the wire, as the wire on the spool will instantly try to un-ravel itself!
All the Best,
CJ

 

[barrygibson]

Also i file the end of the wire so its not sharp.It also aids the wires journey up the liner

 

[VL1500]

Well! Have I come to the right place or what?

Swiss Tony, thanks for the info., the picture is good! Now there's a step by step that even I can understand. My confidence to 'ave a bash at this unsupervised is climbing rapidly!

Country Joe and Barry Gibson, those little tips are received with thanks and committed to memory!

Much obliged you lot, very grateful for the response!

Tony.

 

[Dazbo666]

Another thumbs up for Swiss Tony from me too...
With the description and one simple pic, this newbie managed to get my new mig welder set up and ready to go within minutes

 

[apbellamy]

I've found when starting with a new roll of wire, depending on manufacturer, the end of the wire can be tucked/crossed under another wire. If you don't slip this out then it can result in the wire dragging and the mechanism getting jammed. I think this is to stop the real un-ravelling whilst being unpackaged. Cought me out the first time I experienced it.