on my steel pieces i am trying to test weld too and the wire keeps sticking to the copper coloured tip , i have to then pull out the wire cut it and sort of free it from the tip as it seems to short to the tip
just fitted a new nozzle, spring and tip still same problem …
many thanks jim
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Inadequate shielding gas coverage is among the biggest culprits, and this can be addressed in several ways. First, check the regulator or flow meter for adequate gas flow, increasing it as necessary. Check the gas hoses and welding gun for possible leaks, and block off the welding area if drafts are present.
Your welding wire not feeding properly off the spool is likely due to incorrect tension on either the spool break, the drive rolls, or both. Too much tension can cause wear on the wire and too little can lead to birdnesting, so it`s important to find the sweet spot on both parts.
If the Mig Welder Wire Feed Roller Tension is too great on softer Mig Wires (e.g. Flux Cored & Aluminium), the wire can be slightly flattened, so instead of your welding wire being, say 1.0mm in diameter, it may become 1.1 x 0.9mm, this will then increase the risk of jamming at the copper Tip.
The main reason for pinholes is the presence of impurities in the weld puddle caused by the gases released by the welding gun. This contaminated air is absorbed by the molten metal and causes holes to appear.
Check for proper trim, unwanted kinks, or a buildup of gunk like lube, dirt, moisture, or dust. Any or all of these things could trip up the wire feed. Be sure that the liner coils are tightly wound and have good deflection and rigidity to withstand twisting. This is especially true with long cables.
If your setting gas flow on a Mig or Tig, operate the machine so it`s gas valve is open. Slowly turn the Gas Regulator Control Knob clockwise. When you start to feel resistance the gas should start to flow and the Delivery Gauge Needle will start to move around the scale.
Can any Mig be used for Gas AND Gasless Welding? No, a Mig Welder will be designed to either use Wire with Gas, Self Shielding (gasless) Wire, or both (Gas/No Gas). The difference lies in the Polarity of the Torch. To use Self Shielding (Gasless) wire, the Torch needs to be NEGATIVE (-).
Travel speed too slow: Traveling too slow introduces too much heat into the weld, resulting in an excessively wide weld bead and poor penetration. On thinner material it may also cause burn-through.
Using the wrong type of drive roll or setting improper drive roll tension can also be common mistakes causing of erratic or poor wire feeding in MIG welding. Consider the size and type of wire being used and match it to the correct drive roll.
For MIG short-circuit welding it`s recommended to use a 25 to 35 cubic feet per hour (cfh) gas flow rate. TIG welding typically runs a lower flow rate, while MIG processes using other transfer modes (other than short-circuit transfer) can run slightly higher than 35 cfh.
The ideal pressure range for most standard MIG welding jobs is between 3 to 8 PSI.
Gas for MIG welding mild steel

A 75 percent argon/25 percent carbon dioxide blend (also called 75/25 or C25) works as the best all purpose shielding gas for carbon steel. It produces the least amount of spatter, best bead appearance and won`t promote burn-through on thinner metals.

One of the most common issues in welding is slag inclusion – the small particles of flux that become trapped in the weld metal. Prevent it by using the correct current and voltage, and by making sure your flux-coated consumables are well-maintained and in good shape.
Whether you use the standard torch or a spool gun, MIG welding aluminium requires pure argon gas.
The main differences between MIG welding with a gas or gasless setup is gas provides a more stable, better-quality weld that produces less fumes and spatter. For a nice, clean weld on finer materials, gas MIG welding is preferable.
The sign of a quality and secure weld is that you will not see the weld at all. If there is any visible evidence of a weld, it will be in the form of a bead that has no holes or cracks and is uniform overall. A high-quality weld is made using high-quality materials.
MIG welding works best with aluminum, carbon steel, copper, stainless steel, magnesium, nickel and bronze. It can work with other alloys, or combination metals, as well. It`s known within the welding industry as GMAW, or Gas Metal Arc Welding. Due to the welding method, it`s sometimes called wire welding.
A recommended wire feed speed would fall in the range of 240 to 290 ipm with travel speeds between 14 and 19 ipm. A good rule of thumb is to keep the welding wire stickout at 5/8 inch or shorter for small diameter wires. It helps control amperage and with it, heat input and more.
This common issue happens because of the MIG wire burning back to your tip. This often happens when your wire arcs at the contact tip and welds itself inside the tip. Burnback is solely a MIG issue because it only happens when the wire is continuously fed through a small contact tip hole.
In most cases, the gun should be angled slightly in the direction of motion. This is called the travel angle, and 15 degrees is a good place to start. Looking at the gun from the end of a seam, the angle of the gun to the work is called the work angle. For a butt joint, 90 degrees is ideal.
Weld from the bottom up.

Like building a house, you cannot start the bricks at the top. Weld metal is a liquid. When it goes in it needs support, that is why we need to always start at the bottom.

Both acute and chronic health risks are associated with welding fume. Occupational lung disease, including lung cancer, is the most common health risk, but welding can also affect the eyes and skin. There is also a significant risk from asphyxiation when welding in confined spaces.
Among the commonly known welding defects, incomplete penetration and fusion, porosity and slag inclusions are the most common to affect welding strength.
Inadequate shielding gas coverage is among the biggest culprits, and this can be addressed in several ways. First, check the regulator or flow meter for adequate gas flow, increasing it as necessary. Check the gas hoses and welding gun for possible leaks, and block off the welding area if drafts are present.

Discover Relevant Questions and Answers for Your Specific Issue

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I have a Kohler Condidant 5 Generator that will run as long as you hold the start button in. It dies when you let off. I have a harness for the remote switch but no switch – It also will start the generator when you cross the red and black wire and run as long as you hold them together. There are 3 wires to the main switch and 5 to the remote switch. Does the starter stay engaged the whole time you hold the start switch or does the computer release the starter once it is running? The Generator is producing electricity because I tested it while holding the start button. Some where is a wire that shold tell it to keep running. I have read online many descriptions of the same problem, most are told the board is bad so they replace it and still have the problem. Have not found a solution. Talked to a marine machanic today and he said he fixed his friends generator doing the same thing by running a bypass wire but he couldnt remember exactly what he did it was a long time ago. Can anyone help me. Thank you
ANSWER : The problem is either the ballast resistor or the starter bypass relay. The bypass relay should be part of the starter solenoid. I’m afraid I can’t tell you exactly where the ballast resistor is located. It should be a physically fairly large resistor made of ceramic. It should be retangular roughly 1.5″-3″ long and 3/8″-1/2″ accross with a wire on each end. It could also be a coil of wire mounted on a phenolic board.
If you need more help just add a comment and I’ll respond as soon as I get the message.

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Spark plug wire boot grounding out on coil, 96 outback 2.5 automatic, just put new spark plug wires, new spark plugs, and new coil on. ran great for two weeks, now spark is jumping out of boot at coil on one wire, put old coil back on and still does it in the same spot. replaced wires again, and still does it in the same spot. seems to do it only under a load. Is my new spark plug on that cylinder bad? Does the coil need some insulation under it? It is the coil that sits right on top of the motor. Any ideas? thanks.
ANSWER : Sparks are high voltage, and will always follow the path of least resistance. If you can visibly see a spark (whether in a lighted area, or in the dark), that means either that a plug wire (or coil wire) is open (non conductive), or your have a carbon track on the surface where the spark can be seen, but most likely you have BOTH problems!

If you have an ohmmeter, check the resistance of each wire involved, particularly spark plug wires … which means you must be able to connect to both ends of each wire at the same, and hopefully, FLEX those wires, to be sure they don’t have a break inside that is intermittent (comes and goes)!

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Trying to install a new fluro light, pull out old light to find 3 reds and 3 blacks 1 copper earth. What do I do to connect it up the right way??? When I pulled the old Fluro light out the 3 Reds were joined together with a connector ,two blacks were joined to one end of light wire, the other to the other end of the light wire,earth wire to the light case,the third black wire was connected to the wire from the ballast? Does this all make sense
ANSWER : No, this does not make sense but I have seen strange wiring before. There is power going from the light someplace else. Just connect it back up exactly as the old light was connected. It worked before so it will work again. If it works it is wired correctly. Without being there to check which wire was the hot wire and which was neutral it is impossible for me to say what is what. Make sure you connect the ground wire to the light chassis.

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I bought a new mossberg 590 a1 shot gun a month ago, I love the gun but its having a couple of problems, the first problem is that when shooting every once in a while i get sprayed in the face with exuast from shooting through the safety very scary! any ideas whats causing this? how to fix it? second is that some times the fireing pin sticks and the gun will not discharge a round? the third problem is that i have had feeding issues with gun where it will not realice a gound from the tube, ive taken a tip of a knife to the stuck round in the tube and it prys out with little effort, these problems dont happen every time i go shooting, just every once in a while, but they a happening more and more, im conserned cause the gun is brand new, and i wanna be safe while shooting, can you guys help me? any ideas/solutions? please help!!!!!!!
ANSWER : Personally, with that many problems, I’d call Mossberg and get a return authorization. None of these things should be happening, especially with a new gun.

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Hiya I have a fujifilm e-900 I have used the camera less than 20 times. The last time I used it I had no problems at all. I had left it sitting in it’s case for 6 months. Now when I try and us it I get the hand with lightning bolt on the lcd. Which I assume means the battery encasement is open. It isn’t open. The camera turns on no problem then when I try and use any function it shuts down. How do I fix this?
ANSWER : The hand with the lightning bolt icon usually means the camera is telling you that there is not enough light and you need to pop the flash up before you take a picture.
If you haven’t used the camera for a while have you tried fresh batteries or charged the 2 re chargeable AA’s that came with the camera?

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1996 bayou runs for short time ,keeps stalling out
ANSWER : Hello, I would start first, make sure ex pipe is open . Then I would check the pick up coil, ohms should be 390-590 on a 300 KLF. Do this test before u start the bike Then start the bike and when it quits running check the pick up coil ohms. If good move on to the coil, If good then I would say good chance CDI is bad I hope this helps

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’03 zx600rr clutch,will not adjust
ANSWER : Alright, let’s get nasty. First of all, who makes the clutch you are putting in and what is the part number. I want to set this up myself and see where you are confused.

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