Mig wire size for Quadralink install

[nkopper]

Just got a Quadralink yesterday and hope to weld it in myself. I've been practicing my welding a lot, but having some trouble getting sufficient penetration on 1/8" or 10 guage material. The welder is a Millermatic 135 and I'm currently using L-56 0.024 wire (I know, not recommended for material thicker than 18 guage) and 75/25 shielding gas. So, the question is, what is the best wire size for this install, 0.030 or 0.035? The LWS has Inweld wire, looking at ER70 S-6 spec in either size. They said either would work, it's just up to my preference and welding style (whatever that is). Both are listed as acceptable in the manual for my welder, but opinions from some experienced welders is much appreciated. I've never used anything larger than 0.024.

Thank you,
Nathan

[dontlifttoshift]

With a welder that small I would go with the .030"

[nkopper]

That's kind of what I thought, just wanted to be sure since the local welding shop wasn't much help. I guess if it still isn't sufficient, I could switch to straight CO2.

Nathan

[dontlifttoshift]

Straight CO2 will burn in better but it is an ugly mess compared to the 75/25....Really the thickest thing you are welding is the 10 gauge crossmember and that is only welding to sheetmetal so you should be fine.

I would just tack the brackets on the rearend and get someone with more power to weld those on though.

[exwestracer]

The .030 wire will definitely help, but something else that is very important is the wire length from contact tip to work surface. This gets a lot of people in trouble with small MIGs. You should always have the tip within 3/8" of the surface, and less is better.

If your welder has a threaded gas nozzle, buy a spare one and cut it off 1/8" BELOW the tip for use in inside corner (fillet) welds. The slip on nozzles can be pulled back that far in most cases. The fillets require the most heat, and are the most difficult to get close enough on. Make sure the sheetmetal is absolutely clean at least an inch past the weld location in both directions.

That SP-135 should do the job fine if it's in a good state of tune. Just remember, if it ISN'T welding up correctly, don't keep going! Stop and fix the problem.

[nkopper]

I'm definitely farming out the rear end brackets to an experienced chassis shop. No way would I touch those with a 110 mig.

Good advice, Ray. I'll have to try that with the gas nozzle, never heard that before. Worst case scenario is that I will tack everything in place and get an experienced welder to finish it up. Will practice with 0.030 wire tonight and see how it goes. Just trying to save a little $$ on labor, but don't want to compromise safety in the process.

Thank you,
Nathan

[mikey]

You shouldn't have any trouble welding anything but the housing brackets with a 135. Although you may have to stop and let it cool down from time to time. It's a great little welder I use them all the time for stuff up to 1/8". I have gone up to a 1/4" with it but it was an emergency fix only till I got my loaned out 250 back. Fyi if they don't mention it you will need a .030 liner also

[nkopper]

I tried the 0.030 wire and it acts like a different welder. I can finally burn through 1/8" steel. I need lots more practice to get used to it, but I'm confident I can do it with the small welder.

Nathan

[mikey]

I tried the 0.030 wire and it acts like a different welder. I can finally burn through 1/8" steel. I need lots more practice to get used to it, but I'm confident I can do it with the small welder.

Nathan

Change it back to the .024 when you get back to welding up your sheet metal. It's easier to use it on the thin stuff. Do you have it on a dedicated 30 amp circuit? That will help alot also along with a heavy guage extension cord if needed. I think I made mine out of 12ga.

[nkopper]

Yes, I wired up a separate 30 amp circuit for the welder. Luckily, I don't need an extension cord to reach the car or welding table.

[80proZ]

The switch to .030 wire is the wrong direction! Keep the .024 for anything less than 3/16". The .030 requires more heat just to burn the added wire thickness! With proper prep and technique your 135 is more than adequate to handle any job on automotive fab work. I have a Hobart 135 running .023 wire and have used it to weld everything from 26ga to 1/"2. With absolutely no failures people completely under estimate these smaller welders. And if it makes a difference, I'm a welder by profession for a little over 20 years.

[nkopper]

I ran across a really good deal on a nearly new Millermatic 211 on Craigslist that I couldn't pass up, so no worries about power anymore. I'll be able to weld anything now, even a rotisserie I want to build.

Nathan