Wire size help...

[DRJDVM's '69]

So I'm brand new to welding so I was looking for some info.



I'm taking classes at a local trade school and just purchased a Miller 175 to use at home. I'm not planning on anything of significant structural integrity until I get alot of practice, so most of my stuff will be sheet metal (floor pans, patch panels, brackets etc). I do plan on making an engine cradle and a body cart too, so there will be some structural stuff but nothing on the car itself for now.

So.... the Miller came with a small roll of 0.024 wire and contact tips 0.023 and 0.030....

So from a practical standpoint... which wire sizes and contact tips should I have on hand for these kind of jobs ????

In other words, what wire size and contact tip goes with which material/job ???

[mikey]

I use .035 for most heavy welding frame rails and structural parts. I also use .023 for lighter guage steel outer sheetmetal panels. Your welder should have a setup guide printed on this inside of the access panel it's really close to what you will use. I use a 185 at work we keep .035 in it I've found that I can just adjust the heat and wire speed to weld anything from 22 guage to 3/16. At home I have a 135 that I use .023 in because I mainly just do light sheetmetal welding and I was running out of 220 circuits. Keep in mind when you go from .023 to .030 you also have to change the liner to your gun this can be a pita to do on a regular basis. So my best advice would be to consult the guide on your welder and go from there I hope this helps answer your question pm if you need more help Mike

[parsonsj]

I use .035 for most heavy welding frame rails and structural parts. I also use .023 for lighter guage steel outer sheetmetal panels.

Ditto.

jp

[wendell]

I've never changed the liner in my gun to correspond to my wire size. The first 10 years haven't given me any problems. Could some one confirm that this neecds to happen?

DRJ...
I do agree that 0.023 and 0.035 will cover all your bases with a 175.

[parsonsj]

I change the liner ... I've never tried not to. So no good information from me.

jp

[Matt@RFR]

If you have a stock 8'-10' lead, you'll probably be fine with an .035 liner using .023 wire. A 15' Tweco won't fair so well.

[Modo Innovations]

I also have a Miller 135 and I run .023 in it for everything. Of coarse I just use it for lighter gauge stuff. I have used it on 3/16" tubing before and have had good results. If I need to weld on bigger stuff I use my neighbors Hobart.

[Stoker420]

I never change the liner I use .035 and .023 solid and SS wire. never had a problem.

[martZ]

I have two guns for my Miller 210. I have a smaller M-15 gun with .023 wire and .023 liner for sheet metal work and the standard M-25 gun with .035 for everything heavier. You don't need two guns, it's just quicker when changing wire sizes, plus I like the smaller gun for sheet metal work. Like someone else said, refer to the inside cover on your welder and follow their recommendations.