wire jammed inside mig gun

[evaldart]

Allright, someone must have had to deal with this one before. A friend of mine gave me a 30lb spool of .045 plain steel wire. I changed the tip on the gun (but not the drive rollers because I didnt have the 45's for that). So as I see it, the smaller rollers deformed the damned wire which inturn locked it inside the hose somewhere. And man it is STUCK! Have I killed the whole gun and hose or is there a secret trick to get it out? Or is it another lesson learned through money. USE THE RIGHT DRIVE ROLLERS STUPID!

And, for future uses...is 45 more trouble than 35 on the Millermatic 250? Maybe my machine isnt powerful enough.

Input much appreciated.

[jOe~]

Maybe the liner ain't big enough. Like using a condom that's too small (but then a deformed one might not fit either)

[EJB]

Unless you really have your drive rollers cranked down, it's more likely that the liner in your gun is too small or was really dirty. Main thing required here is finesse and patience. Take it apart as much as you can, shoot a little penetrating oil in the ends and if you have an end of the wire exposed, hold it in a vise or with some pliers and GENTLY wiggle and wobble the entire length of the liner while trying to ease it out the same way it entered. Depending on the type of gun you have, you should be able to completely remove the liner and replace it if necessary.

As far as the undersized condom dilemma; follow the same instructions above, apologize profusely and state that you would like to remain friends.

[jOe~]

someone must have had to deal with this one before I forgot to reply to this part. The answer is no.

[underfoot]

I've had problems with bigger wire (particularly stainless)
a sharp end on the wire has punched thru the liner and fed up into the outer sheath and jammed, usually filing off the point and re feeding it works for me,
can't imagine the feed rollers distorting the wire, but then you've probably got the family size MIG

[grommet]

well that does make sense... Maybe put on some of Glenn's Mahler music and patiently, catatonically back the wire out.

[PTsideshow]

Liner should come out then you can work on it, I have a liner for the aluminum wire and spool. And yes you have to change the drive rollers to eliminate problems. Along with the correct size liner.

Do you have any idea how far it got in the liner before coming to a halt. Clamp the MIG wire in a vise and start working on the liner to move it in the opposite direction. If it is a wire wound liner shoot your favorite WD-40 Oil in it and work the liner off. It is a slow process.

But the one good thing is I was told that if you are half smart you only do it once. When you are done!;)

I know I will never try to do that again:rolleyes:

[evaldart]

Ed, I didnt realize that the liner could come out and get replaced. If so, thenthats the route. Thanks. I'll be needing to muster some patience though...cant remember when I did that last. I'll probably go buy a new kit straight away. Its 250 bucks for the good one; and they last ten years...even for Evaldart. Then one day when I've got the flu or am terribly hung-over I'll go out and deal with that patience thing. You know, instead of sweeping or sorting the nuts and bolts.

thanks guys

[PTsideshow]

Forgot to mention that after removing the wire soak the liner in some form of oil remove appropriate to the liner material. To clean it up before youstuff it back in the assembly.
:D

[rustyjames]

I would imagine if you were to soak a liner down with lubricants, the liner should be flushed out with some kind of solvent. Otherwise, the wire will become contaminated, causing poor weld quality.

[The Forge]

I would replace the liner. Small price to pay for peace of mind.