I am using .035 solid wire putting in my floor pans. (I wanted some good practice before I tried the quarter panels.) I am getting good solid welds with plenty of penetration and only had a couple of burn through spots and I was able to fill them. The problem I am having is the welds are BIG! I am sure they are strong but there would be a lot of grinding if it were a finished surface. I tried a lower heat and they got bigger, a higher heat and I burned through. I was thinking of a smaller wire. I am using 30 PSI of 75%/ 25% gas. Anyone have any recomendations?

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1969 Camaro 350 & 1969 Impala SS 427/ 4-speed (restored)

I always use 023 on any sheet metal welding. I wouldn't use that big of a wire unless I was welding a frame, it can be done but the 023 is easier to work with.

Use a 022-024"wire, turn your wire feed speed down so that the wire is burning off a little higher than normal and point the gun in the direction you're going leaning it backward from 15 to 35 degrees. This will welp your weld to lay flat.

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74 Camaro
in the Great White North

I thought the wire size was the answer. I got a lot of the .035 for free. I guess I will buy some .023 and a tube and give that a try. Gas sound ok?

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1969 Camaro 350 & 1969 Impala SS 427/ 4-speed (restored)

Gas sounds good to me, and the wire size should fix you big bead problem.

Mike

I had the same problem, only I was using flux core wire and .030 wire. I changed to a .024 solid wire and gas shielding and man, smmmmoooooottttthhhhhh. I also bought the Haynes Techbook on Welding (blue cover), it is GREAT for explaining all the different types of welding, as well as making wire selections and gas selections. They mention and "Easy Grind" wire by L-Tec for body work, and I have a friend who swears by the stuff. I think it also recommends using filler wire that is the same thickness as the metal you are welding. Good book, good price ($15 bucks I think).

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Bing
1956 Chev 150 2dr sedan 302ci
1965 Chev Malibu 2dr hdtp 496ci
1967 Chev Camaro 327ci
Check 'em out at: http://www.members.home.net/mgbing/cremcars.html

Just a reminder...remember to switch your polarities when going from flux to gas. Also, watch out for warping on those quarters. Some guys put wet rags near the weld to minimize the heat warpage.

good luck!

Does anyone know where I can find the EZ-grind mig wire, have ask a couple of shops around my area and havent had any luck. thanks

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69 rallye green X77 Z/28,1967 SS 396 Conv. 1974 c-10 454 swb

The Miller distributor in my area has never heard of EZ grind either. When I stopped by to pick up some .023 wire I found that Miller does not make a .023 tube for the " Spoolmatic I" gun I have. I am going to have to try to run .023 wire through a .030 tube. Hope it works. Any one know where to mail order welding supplies? They had to special order both the .023 wire and the .030 tube which is the smallest they make so I have to go back. What a pain!

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1969 Camaro 350 & 1969 Impala SS 427/ 4-speed (restored)

DanB,
I'm consulting with my dad right now, he's a DM for Miller Electric, Western PA, NY, OH, WV...will post answer when I have one...

Mike

.023 wire at 15 psi works great. Using a scrape piece of metal, lower your PSI until the welds look like theres a lot of little pinholes, then increase the PSI by 2. Too mush PSI is just wasted gas. It'll be about 10-20 lbs. We use CO2 instead because we go through a lot at the school and it cost less.If you have a good welder, have the setting right on, and have good welding skills, you shouldn't have to do a lot of grinding.

Got some answers for you, the "Easy Grind" wire you refer to was more or less an advertising term for Linde/Esab wire, and isn't a specific type of wire.

As far as the gun and tips, they have a conversion kit for your gun that would allow you to use the newer short style tips. They don't make the longer style tubes that you use in .023, but after getting the conversion kit you would have much more choice in what you could use.

My dad gave me a Miller part number for the conversion kit that you should be able to get from a Miller dealer.

The conversion kit is part # 156485 and retails for $84. The .023 contact tip is part # 136171 and retails for $1.29.

He also recommends ordering 70S-6 wire, he says it's a good wire for body work.

Hope this helps, any ?'s let me know.

Mike

Millers site www.millerwelds.com (http://www.millerwelds.com)

So is the 70s-6 wire you refer to made by Linde/Esab and is that the part #. Do you know any links for it?

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69 rallye green X77 Z/28,1967 SS 396 Conv. 1974 c-10 454 swb

Mike, thanks for the help. I tried the .023 wire in the .030 tube and it is much better but not yet perfect. I am going to look into that conversion kit. My nozzle is pretty messy anyway. Thanks for the numbers the Miller rep. in my area leaves a lot to be desired and having the numbers is a great help. This .023 wire I have measures almost .030" even though it clearly says .023 on the spool. Is this common? The Miller rep says wire is always oversize and varies. True??

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1969 Camaro 350 & 1969 Impala SS 427/ 4-speed (restored)

My dad did say something to that effect, I don't think it varies as that guy told you, but my dad did say the wire is made bigger than advertised as. I think he said the .023 actually is a .028 wire, and the .030 is actually a .034 wire.

Good luck, if you need any more info, let me know, and I will give you my dad's # or direct e-mail.

Mike