How to Convert a Wire Welder to MIG

Most welding machines can be converted between flux core welding wire to solid core MIG wire for welding.

Arc welding machines can generally be used for two types of welding applications that require simple modifications to the machine's configuration and settings. Flux core arc welding (FCAW) uses a welding wire that contains a resin that when burned creates a shielding gas to protect the weld bead from contamination. Metal inert gas (MIG) welding, otherwise referred to as gas metal arc welding (GMAW), uses a separate source of shielding gas from an air tank and a solid core wire setup. Changing the welding machine between FCAW to a MIG setup is just a matter of a few simple steps.

Things You'll Need

• FCAW/GMAW compatible arc welding machine
• Solid core MIG wire
• Solid core wire drive roll
• Tank of shielding gas
• MIG welding torch assembly

Instructions

Remove the Flux Core Setup from the Welding Machine

1. Unplug the welding machine.

2. Open the access hatch on the side of the welding machine to reveal the flux core wire spool and wire feeding assembly.

3. Turn the wire spool clockwise to reel the flux core wire back onto the spindle.

4. Pull the flux core wire spool off of the spindle and remove it from the machine.

5. Raise the wire tension arm to reveal the flux core wire drive roller.

6. Pull the flux core wire drive roller by pulling it up out of the drive assembly.

7. Unplug the FCAW welding torch assembly from the front of the welding machine by disconnecting the wire bushing from its socket on the face of the machine and pulling out the wire feeding hose.

Install the MIG Setup for the Welding Machine

1. Attach the solid core MIG wire torch assembly by inserting its wire feeding tube into the front of the welding machine and plugging in the torch's wire bushing into the socket on the machine's face plate.

2. Insert the MIG wire drive roller in the wire feeder assembly on the inside of the welding machine.

3. Place a spool of solid core MIG wire onto the spindle with the wire feeding toward the front of the machine.

4. Feed the MIG wire through the wire feeder assembly, over the MIG wire roller and into the torch hose through the back side of the machine's face plate.

5. Lower the wire feeder assembly's tensioner arm to lock the wire in place and close the hatch on the side of the welding machine.

6. Plug the solenoid hose from the shielding gas tank into the gas coupling inlet on the back of the welding machine.

7. Reverse the polarity of the arc welding machine. Most machines have a polarity switch or knob on the front of the machine that have specific labeling for flux core and MIG welding applications.

8. Plug the welding machine in and depress the trigger on the welding torch gun to feed the MIG wire through the hose and through the tip of the MIG torch.

Tips & Warnings

• Review your manufacturer's operation guide for your welding machine for information specific to your machine. Some welding machines require the wire to be fed over the top of the spool, others require it to be fed from under the spool.

• Always secure your shielding gas tank to the wall with a heavy chain prior to operating your welding machine as a MIG welder.

References

• Lincoln Electric: Wire Feeder Welder Operator's Manual (Pro-MIG 175)
• Lincoln Electric: Wire Feeder Welder Operator's Manual (125, 140, 180MODELS)
• Miller Welding: Millermatic 140 Auto'Set and 180 Auto-Set Owner's Manual
• Miller Welding: Millermatic 150 and M-15 Gun