# of FAQ's Filtered:

ITEM# 57901 has a black sleeve and ITEM# 57902 has a red sleeve.

Our part number for the requested part is 85263.

We do have a 10' torch assembly for your Clarke welder. It's our ITEM# 84909.

Welding on cast iron requires the part to be preheated. One article I read suggested 500 to 600 degrees, and I've heard it may need to be as much as 2000 degrees. If the part isn't preheated, and even if it is but doesn't get hot enough, the application of the electrode will generate heat and when that hits a cold spot will crack the cast iron, further compounding the issue. If you opt to go ahead with the welding, we recommend our 55% Nickel "Super Ni-Cast" rod, or our Super NI-Cast 99% Nickel. The 55% has a higher tensile strength and typical applications are Grade 30, 40, and 50 cast iron, and the 99% indicates a typical application would be engine blocks. Another option would be to drill the holes out, tap them, and put a threaded insert in. The stud could then be threaded into that and would eliminate the need for the welding. Your local parts store should be able to assist with that if that's the way you decide to go. Please remember that the primary component of the welding process is the preheating. 

The rod recommended would be determined by a number of factors: load stress on the weld, condition and type of base metal, anti-corrosion or hard-surfacing requirements, etc. Any information regarding these factors would help us narrow down the range of options for you. Information and suggested applications on each type of rod we offer is also available on our website at the digital catalog under the store header, sub header: ARC welding electrodes.

Both models are discontinued and not available any more. The 390 is not recommended for use with a generator because of attendant surges which can damage or destroy the power source. You can use a generator on a few of our other welders; the 140 MIG minimum generator power required is 6 KW, the 190 MIG minimum generator power required is 8 KW, the 210 MIG minimum generator power required is 9 KW, the 270 MIG minimum generator power required is 13 KW, the 140 MP minimum generator power required is 6 KW, the 190 MP minimum generator power required is 8 KW.

Our welders are made to our specifications at a state of the art plant in Italy. The same plant produces the MIG welders offered by other large retail chains.

We appreciate your interest in our products. We discontinued that item over a year ago, and have no more in stock. There may be some reconditioned 'as is' units available on various internet sites, but none from Forney Industries.

We would recommend using 10/3 wire to be able to access the higher amperage available on that machine.  However, we do not recommend extension cords longer than 25 feet.

A unique feature on that specific economy welder is that the gun is 'live' whenever the welder is 'on'. So the best safeguard against undesired contact would be to have a piece of non-conductive material on hand to rest the gun on between welds when the machine is on.

The 215 welder has been discontinued. Please check https://www.forneyind.com/store/category_detail/?product_category_id=581 for our current product listing. 

With left being the 'off' position, so to speak and sequencing being top, then bottom switch, the lowest to highest voltage would be as follows: off off, off on, on off and on on.

We offer 3 4-packs of contact tips: 60171 for .23 wire, 60172 for .030 wire and 60172 for .35 wire, an 85316 shield gas nozzle and an 85295 gas diffuser for that model.

The Forney part number for that contact tip is 60165 and that comes as a 3 pack.

A Miller machine we offered for a few years in the '90's is the only literature we have on that. The only parts that we offer, through our extensive dealer network, are the male plugs (#57903 black sleeved & #57904 red sleeved) and universal leads components. Miller might still offer some other parts.

For welding aluminum, an aluminum wire will be required as well as gas. Argon will need to be used in this application. For stainless steel, likewise a stainless will be required. You can use either argon or CO2 on this wire. Mild steel flux core wire is best for thin gauge mild steel and doesn't require the use of a shielding gas, although it can be used. Mild steel wire does require the use of a shielding gas. You can also use either argon or CO2 on this wire.

For welding cast iron, stick welding is the preferred method. Cast iron is often contaminated and the flux on the stick electrode can bind with the contaminants so a good weld is produced. The electrode that usually produces the best results is a 55% Nickel rod.

Please remember that there are many types of cast iron and some are too crack sensitive to be welded.

If you want to repair a cast iron with welding:
• Preheat the piece to about 500-600 degrees F
• Weld short welds
• Peen immediately after welding
• Grind an areas that might create stress concentrations
• Slow cool by wrapping in a fire blanket or burying in dry sand

Those capacitors are 370V. A couple of places where you might find them are: Galco Industrial Electronics
800-575-5562 and Packard, Inc.800-334-1769

The 85359 will indeed fit the Clarke WE6540 regulator.

Was the regulator and barb a Forney product? We do have an adapter, 85359 is our item number that will work for the connection. It's a quick connect type device that the gas line goes inside of. If you need one, it's available on our website at www.forneyind.com.

The warranty for the welders is: 5 year on the transformer, 3 year on the rest of the internal components, and 1 year on the MIG gun, relays, contactors, regulators and accessories. You might check with an ACE Hardware location in Augusta to see if they have one available. The next nearest dealer I can find is in Thomson, or Aiken, SC.

Did gas flow through the gun after you connected the hose, opened the valve, and pressed the trigger? Being a new setup, it may take a little while to get the gas through the line.

How long have you had the unit? We need to make sure it was registered online. If that hasn't been accomplished yet, please do so at your earliest convenience. I don't believe the oily substance is dangerous. In order for us to determine if it can be repaired or if it would be eligible for a warranty replacement, you'll have to send the unit back to us for inspections. Please include any documentation you may have and put a note in it as to what happened and what you were doing at the time it happened. Please box the welder up with plenty of packing and return it to:

Forney Industries
3900 Canal Drive
Fort Collins, CO 80524.

Unfortunately, I don't have a schematic for the Clarke 190 EN welder to confirm or not the fact that the gun for the 180FI will work. We only sell these as a torch and gun assembly under our ITEM# 85263.

We do have the parts you need available. Our part number for the nozzle is 84901, for the torch neck with diffuser it's 84902, and the tips are as noted below: .023, 85346. .030, 85347. .035, 85348. .045, 85349. 

We don't have a spool gun that will work with your welder. We recommend replacing the liner with a Teflon one, our SKU 85354 which will also require a connector, SKU 85307. 

What size of spool are you looking for? We have it available in 2# our SKU number 42290, and 10# our SKU number 42285.

We don't carry parts for the Hobart Beta-MIG 200 unfortunately. I'd suggest contacting Hobart directly at 800-626-9420.

Unfortunately we don't have the parts for these welders any longer. Please contact L.B.L., Inc, 700 E. Elm Avenue - Unit B, La Grange IL, 60525. Their number is 708-579-5893. They are the US representative of the manufacturer of these welders. 

Unfortunately I don't have a spot welding nozzle that will work for your Hobart welder. I'd suggest contacting a Hobart service center in your area and see if they can assist.

We have a 1/0 cable that will work for your requirement, although a 2/0 would work better. We can get the 2/0 as a special order item. The 1/0 is immediately available.

We don't have any parts for these welders available any longer. I'd suggest you check with a local electrical supply shop and see if they have one that will work. I can't comment on the Lincoln one you found as I don't have specs available.

You can probably find one at a local electrical supply house. We don't have any of these available anymore.

We do carry aluminum MIG wire that is 33,000 PSI. We have one pound rolls in both .030 and .035 diameter.

Suggested retail for the #880 is $131.72 and on the replacement cutter #887 is $99.00. They are only available through our dealer network.  Please contact us and we can direct you with more information.

The nearest service center is Advanced Welder Repair at 4903 Washington Blvd. in Commerce City, Ca. Their phone number is 323-263-7383.

I'm sorry but we do not have a service center in the state of New York. The nearest is Rescue Welding, 20 Rescue Lane Somersworth, New Hampshire. Their phone number is 603-692-9940.

The nearest service center to you is Advance Welder Repair 4903 E Washington Blvd, Los Angeles, CA 90040. Their phone is 323-263-7383.

The nearest service center to you is:

L.B.L., Inc.
700 E. Elm Avenue, Unit B
La Grange, IL 60525
(708) 579-5893

The 180FI has 10 heat setting and 3 wire speed settings. The unit is manufactured in Europe to our specifications.

Unfortunately we won't be able to quote on this product. The largest flux core wire we have available is a .035 wire on a 10 pound spool. Thank you for your consideration.

The item you are looking for is our item number 57501. It is not available on our website but any dealer in your area that carries our brand can order it in for you. 

The 318 (190 MIG Welder) and the 311 (210 MIG Welder) both have a six tap position for voltage adjustment and infinite control over wire feed speed (WFS) which is also related to amperage. Often there is a misconception that a "tapped" machine is limiting in what you can do. Rather than being limiting, it takes a different approach to dial in the arc versus having both the Voltage and WFS set as infinite. If you think of the voltage tap settings as 1/16" thickness increments, this will help a lot.

Tap Setting related to Material Thickness that can be welded in a single
Tap 1 = 1/16" Material Thickness
Tap 2 = 2/16" (1/8")
Tap 3 = 3/16"
Tap 4 = 4/16" (1/4")
Tap 5 = 5/16"
Tap 6 = 6/16" (3/8")

The key to using a tapped machine is too first select the appropriate tap setting for material thickness and then vary the WFS which also affects amperage to dial in the optimum arc characteristics. Once you use this approach, you can dial in an arc very quickly and it's not limiting at all.
Often welders take the opposite approach and set the WFS (amperage) first and then dial in the voltage which is fine as well, if the machine is not a tapped machine. Both approaches can easily optimize the arc.

Another benefit to being a tapped machine, is they tend to be more reliable over the long term and if something does go wrong, they are very easy and inexpensive to fix.

Both the 190 MIG and 210 MIG can weld anything from thin sheet up to 3/8"
in a single pass. Thicker plate thicknesses can be welded with multiple passes. Optimizing the arc for material thickness is very easy.

The 235 Arc welder is a transformer based machine and all transformer based machines are more sensitive to input voltage fluctuations than inverter based machines. The 235 Arc welder can operate on lower voltage but reduced output is likely. Brownout conditions can also affect welding. Voltage fluctuations will not typically damage the welding machine (depends how severe) but will often frustrate the person welding. If I were choosing a welder for a class environment, I would lean more towards the Forney 190 MP which is an inverter machine that is capable of MIG, Stick, and TIG DC.

It's more versatile and will compensate better for power changes or fluctuations. The 190 MP can even operate off 115V with the included adapter (however overall output would be reduced).

The Easy-Flo Brazing rod (Cat # 46111) is a self-fluxing rod. The "as brazed" tensile strength is 35,000 PSI. Attached is a technical bulletin for the Easy-Flo product. This product is applied via oxy-fuel/brazing.

As for the using Bare Aluminum rod, the tensile strength is lower at 29,000 psi. This product requires a flux if being gas brazed. However, the recommended application process is oxy-fuel/brazing, but it can be applied with air/acetylene or TIG processes.

Finally, refer to www.jbweld.com for information on the epoxy you want to compare. However, based on a quick review of their site it seems that the epoxy provides tensile strengths of about 3,900 psi which is ~1/10th the strength of brazing with Forney Easy Flo. Application does not require a torch.

1. Read the manual from cover to cover. Do not assume you already know how to weld or this machine is just like all the rest.

2. Check and see if the switch in the on position. Turn it off before you plug it in. The machine will not be damaged if you plug it in with the switch in the on position, but turn it off to avoid any arcs and sparks that could occur if the leads were grounded.

3. Page 15 of the manual number 17 slope up time regulation potentiometer, was turned to the full on position. Turn it down to zero, the only time you would use this is if you are welding stainless steel.

4. Page 15 of the manual number 18 burn back time regulation potentiometer (B.B.T), was in the full on position. Turn it down to zero, the only time you would use this is if you are welding flux cored wire and the wire is burning back into the tip.

5. Page 15 of the manual number 19 polarity change terminals for the Euro socket. Make sure you check the polarity before you weld! Gas is for solid wire, no gas is for cored wire. The wrong polarity setting will make any weld demo fail due to poor weld bead appearance.

6. Use the right shielding gas for the correct weld process. Check the set up guide’s on pages 16, 17,and 18 of the 190 MP owner’s manual.

You can use the Forney TIG torch or any 17V style torch with a size 25 dinse style connector.  The MP machines do not have a gas solenoid for TIG welding so a TIG torch with gas valve is necessary.  The “V” in 17V indicates the torch has a gas valve.  The Forney TIG torch has a trigger that connects to a 7 pin Amphenol style connector that allows you activate the arc with the trigger.  A traditional non-trigger torch can also be used with a lift-arc technique.  The output is DC only and suitable for welding various steels, and some stainless steel.  The Forney MP machines are not A/C, pulse, or high frequency capable so welding aluminum is not recommended.

No, but you may find it helpful.  The TIG pedal hooks up to the Forney MP machines by way of the 7 pin Amphenol style connector and allows the user to “remotely” control the welding arc and current.  If you use a foot pedal, the machine would need to be switched from local to remote.

It depends to some extent on base metal and thickness but most TIG welders will use 100% Argon.

 TIG welding is usually reserved for very precise welding or where the highest quality of weld is necessary.  Often it is much easier or quicker to MIG weld or stick weld.  Personal preference is a factor.  Most find that MIG welding is the preferred method of welding since it’s fast, easy, and good results are possible.  Some welders also prefer stick welding as it’s more portable and better for field repairs on dirty or rusty material.  Stick welding is also very versatile as you can easily weld steel, stainless steel, and cast materials with a quick change of the electrode.

It depends on what you intend to do, but for everyday versatility we suggest to run an .030” diameter solid ER70S-6 wire with a 90/10 (Argon/Carbon Dioxide) gas mix for welding in the shop and then have a variety of stick electrodes for welding outside or on stainless steel.  To weld Aluminum, opt for a Spool Gun setup and run 100% Argon.  It’s not recommended to use the TIG option a lot because the MP machines will MIG weld sheet metal very well.

The Forney 190 MP has maximum versatility and can be run off 220/230 or 115 volts or a generator.  It can weld steel, stainless, aluminum and a variety of other metals with the right setup.  You could weld thin sheet metal up to thick plate (with multiple passes) and you could weld indoors or outdoors.  The arc characteristics and ease of use are fantastic.

It depends on how thick of material needed to be welded, but in reality the .030” wire diameter is probably the most versatile.  With an .030” wire you have the ability to weld thin sheet up to thick plate (with multiple passes).  The .030” wire also gives the welding machine a larger wire feed speed range to optimize the arc characteristics.  Some people will argue the .035” wire is more versatile and this is true if you are using a 200A+ machine, but on a machine that’s less that 200A, go with .030”.

Yes, our ITEM# is 46111.  It can be used with either oxy-acetylene or propane torch and has a melting point of 732 degrees.  

The pre-manufactured cables for this unit aren't available any longer. We do have the components available though.  The cable size is 1/0 and everything is available on our website.

I just received confirmation from our Product Line Manager that our plasma cutter, model 317, doesn't have a problem with dry air.  As a matter of fact, we've added driers to the new versions we have coming in.  Moisture in the air can cause a short in the torch.

Instead of using a brazing rod and your oxy/acetylene set up, a better solution would be the use of stainless steel MIG wire, TIG welding, or maybe a stainless steel arc rod.

Sounds like a problem with the rectifier. MIG's really only weld well using DC current, if the rectifier has an internal short, AC gets through to the arc. This can cause all sorts of problems, lack of penetration being one of them. Checkout internal connections between the transformer and choke because if the power cannot get through, the wire won't melt properly. We do have rectifiers available.  Our SKU is 84994.

I believe the 60325 will work best.

This flux is fine with tin/lead, tin/silver, and other tin alloy solders.  However, it cannot be used on Aluminum or Magnesium.  

 The 140's have an 8' and 190's on up have a 15'

They use Tweco #2

Yes, except the 270 uses Tweco #2 because the higher output would burn up a Tweco #1.  The 210 MIG is unique.

 190 MP, 235 Arc. The 140 MP does not have enough output to run a 5/32".

The wire diameter is too big for that machine.  An .035" wire is max and we recommend a .030".

Start at one end and work the other (gas = 100% Argon, drive rolls = U-groove), lighter tension on drive system, Teflon liner (special order), and maybe a larger diameter tip.  Also use a larger diameter wire like .035 or even .045 so it's stiffer and easier to push.  Remember a spool gun works best and it's difficult to push aluminum wire 12'.

It depends on how thick of material you are welding but .030" is by far the most versatile for 140 to 210 sized machines.  With an .030" you will get a wider arc sweet spot and be able to weld sheet metal up to fairly thick.  If in doubt, use .030".  That goes for FC and solid.

Start at the despooler and work forward. (Wire size, cleanliness of wire, despooler tension, is it paying off correctly, drive tension adjustment, drive roll size, guide tube alignment, burr on liner?, correct liner size, liner dirty, tip size correct.)

Check for leaks, type of gas for material, dirty material, dirty or rusty wire.

Spray transfer requires a high output welder (the 210 MIG or 270 MIG), the right shielding gas (90/10 Argon/CO2 mix), the right voltage setting for the proper wire size (the 210 MIG can spray transfer .030” on tap setting six, while the 270 MIG can spray transfer .030” and .035” wires but usually you have to be in the top two voltage tap settings).  While welding in the spray transfer mode, the weld will produce a humming sound with almost no spatter while the short arc transfer produces more of a crackling/buzzing sound and very fine spatter.

Yes, they all use the same but there are drive rolls for different diameters and some dedicated to FC, some for aluminum.

Make sure everything else is turned off using that circuit, and we recommend a dedicated circuit for a welding machine.  A welding machine will use all the power you can give it.

The wire feed is probably set too high for the specific voltage you are at.  What are your settings and diameter?

Gas isn¹t required for this particular SKU, although you may use gas if you¹d like.

When you change from MIG to FC MIG you then have to change the ground clamp position (it essentially reverses the polarity on the machine) and if you go back to stick welding and it’s on FC MIG then polarity is backwards.

Both .024" and .023" are correct but .024” is a little more common and what we use for MIG wire in our catalog.  It’s a rounding issue plus MIG wire has a .003” tolerance in diameter

A little bit of a tolerance issue, some say 110V, some 115V and some 120V and all can be technically correct.  I would go with what’s on the front of the welding machine.

The machine can use .035” but it doesn’t do well with that diameter.  I recommend no larger than .030” as the performance of the machine will be better.  

There are a number of ways to join various types of brass, bronze or copper materials.  The most popular method, especially with artistic work, is to "silver solder" (technically - silver brazing) the alloys together.  It's generally recommended you use a brazing product with at least 15% silver as this will allow you to join almost any copper or brass alloy to another.  Some will use a silver brazing alloy with up to 56% silver content.  But with that much silver, the brazing rod will be very expensive.  Most people use an oxy-acetylene torch for brazing.

For a secondary choice, many artists use TIG welding, although this requires more skill than brazing.  A silicon bronze filler material is often used.  Some prefer to Stick weld which is a good choice for particularly thicker sections over 1/8".  For Stick welding, a silicon bronze or aluminum bronze electrode is a popular choice.  If color match is critical, then finding the right filler material can be very difficult and time consuming.  For lighter color bronzes, use an aluminum bronze, and for more of a reddish bronze, use a silicon bronze filler metal.

Any time you are working with copper or brass products that are thick or large, preheat is often used since copper has such a high thermal conductivity.

We recommend TIG welding with AC, 100% argon gas, and 2% Lanthanated tungsten.  The most common filler metal is ER4043.  For welds that need higher strength or will be heat treated, the ER5356 is the best.  There are many types of AC TIG welders, I would recommend one of the newer inverter style machines because you can adjust the AC parameters and really dial in a beautiful weld.  The Forney 220 AC/DC is a good choice.  Artistic TIG welding on aluminum will take some time to learn even if you TIG weld steel or stainless steel on a regular basis.  Once you learn the TIG machine and the potential adjustments, the results can be spectacular.  I always recommend using a foot pedal if possible as this helps you better deal with crater cracks by slowing down the amperage at the end of the weld and helps control the heat.  Some common settings for aluminum is: balance at 60-70% EN, frequency of 60-90 Hz, 0.5 second pre-flow, and 4-8 seconds of post-flow.  Some welders also like to add pulsing while working with aluminum.

Preheat on thicker section or large material is often needed because of the high thermal conductivity of aluminum.

Most people will use a 308L electrode or wire for joining 304 stainless steel (which is by far the most popular stainless base metal).  You can easily join stainless steel with MIG, Stick or TIG welding.  It comes down to speed, precision, and location for which process will work best for you.  If you are working inside and need a perfect weld, then use TIG with 100% argon and a ER308L rod.  If you need speed and a good looking weld, use MIG with a 98/2 shielding gas and a ER308L wire.  If you are doing outdoor work, then use Stick with an E308L electrode.

This is one area that Forney is particularly strong in. We offer everything from entry level welding machines to light industrial machines, torches, plasma cutters, and filler metals. The following are some recommendations:

Welding Machine: I would recommend the 190MP which is a Multi-Process machine, capable of MIG welding, Stick welding, and TIG welding. This machine is ideal for a fairly advanced DIY artist. You can plug it in to 230V or standard household 120V with the included adapter. Depending on the type of project or artwork he is creating will dictate what welding process is best. In this case, he has three processes to choose from. This machine gives him a lot of capability to grow into. The spool gun and TIG torch are sold separately.

Plasma Cutter: I would recommend the 325P Plasma cutter which is good for cutting thinner material up to about 3/8" of an inch. Artists often like to cut out intricate metal shapes, this is a good choice that provides a better quality cut than an oxy-acetylene torch. With this plasma cutter, you do need a compressor to supply the air flow. The compressor should have a filter in place to eliminate moisture and contaminants from entering the plasma cutter. This machine is very easy to use.

Filler Metals: Most artists are working with steel or stainless steel. For steel MIG, I would recommend ER70S-6 MIG wire with a 90/10 shielding gas. For steel stick electrodes, I would recommend either E6013 or E7014 electrodes in the 3/32 & 1/8" diameters. This leaves a nice looking welding bead and they are easy to use. For stainless steel, a ER308L MIG wire or E308L stick electrode is appropriate for most applications.

Accessories: Don't forget an auto darkening helmet, welding gloves, chipping hammer, wire brush, safety glasses, cutting and flap disc abrasives to make sure he has all the accessories he needs to get started.

Unfortunately, Forney Industries doesn’t offer a TIG torch with a fingertip control.  These are not popular in the U.S.

Our TIG torch has an on/off switch that connects to the amphenol connection.  It is a 17FV so it has a flex head and valve.  If you use a foot pedal you do not need a trigger torch. 

Yes, the 85363 regulator is compatible with Hobart welders.

Those machines use the 60170, 60171, 60172, or 60173 tips depending on the size of the wire being used.  The 60170 is for .024" wire, 60171  for .030" wire, 60172 for .035" wire and 60173 for .045" wire.  These are 4 pack SKUs but we also have them available as single tips: 85346, 85347, 85348 and 85349 again depending on what size wire is being used.

The required amperage for the 140 MIG machine is 20 amps.

The Forney 140 MIG as well as other high output 120V machines often produce end-user frustration due to the breaker popping and needing to be reset.  This is a common problem and is very noticeable if the customer is using a 15 Amp breaker, using .035” wire, or is pushing the wire feed limits of the machine while on tap setting 4.  When designing a 120V machine, there is a balance between maximizing the output of the machine or never blowing a breaker, but having a poor output machine.  We chose to maximize the output of the machine as the machine settings can always be turned down.  The performance of the Forney 140 MIG machine has the highest rated duty cycle and output at 90A at 35% in its class.  If you are frustrated by a breaker popping, try reducing the tap setting, reduce the wire feed speed, reduce the wire diameter, or get a less capable machine.  Also, verify the breaker output and have an electrician install the largest breaker that can safely be used per electrical codes.  The chart below will provide some guidance:

140 MIG reference.png

The below PDF lays out the different welding processes, metal uses and also has a couple of charts on general welding information and recommendations.

Helpful Welding Information.pdf

Both the electrode holder and ground clamp connections require a size 25 Dinse connector.  A Dinse style connectors pushes in and with a quarter turn, locks in place.

Euro Connector – the Euro connector is for a MIG welding gun.  The larger hole is where the wire goes, medium size hole is for the gas and the two small holes are what control the trigger.  The brass casing transfers the welding power.

Dinse Connector – is a type of connector for welding cables, ground clamps and electrode holders.  It’s a male/female type connection that transfers electrical power. It is usually electrically hot.

The 125 FC machine is capable of welding 1/8" steel and the plug can be 15 amps but the breaker should be 20 amps. The power cord uses a 15 amp cord. 

You can weld aluminum with the 140 MIG, but it's not capable of using a spool gun.  We suggest you change the liner in the lead to a Teflon or plastic one instead of the steel liner that comes in the lead.  Aluminum wire is a lot softer and can get caught in the steel liner and cause lots of issues. 


Our part number for that liner is 100357 and our suggested retail on that one is $32.55.

For DIY or for any machine under a 200 model, we recommend .030”.  You will get better performance, more versatility, and a wider sweet spot.

No, you cannot weld aluminum with an Easy Weld. If you have the Forney Easy Weld 100 ST Stick machine, you need more amperage than the 100 ST puts out and aluminum stick welding is not easy.  If you have a Forney Easy Weld 125 FC MIG, there is no aluminum flux-cored wire.

No, you would need an AC TIG machine with HF (High Frequency) start for TIG welding aluminum.  However, you could MIG weld aluminum with a 190 MP machine if you purchase the optional spool gun.  Remember, when you weld aluminum, you will need 100% Argon gas.

Here are a couple of common issues:

  1. Electrode choice:  We recommend the Forney E6013 & E7014. The Forney brand performs very well even up to a 1/8” electrode.  Other brands of electrodes often require more amperage.  Some types of electrodes like E6010 and E7018 also require higher amperage and may not be the best choice for the Forney Easy Weld 100 ST.  An E6011 can also be used.  Some electrodes and brands will be limited to the 3/32” diameter because of their amperage requirements.

  2. Use of extension cords:  If you need to use an extension cord, we recommend a 10 gauge cord, no longer than 50 ft. or a 12 gauge at 25 ft.  A small gauge extension cord like 14 or 16 gauge will choke the incoming power and reduce your power output which will create frustration.

  3. The ground is attached to painted or coated metal.

Here are a couple of common issues:

  1. Check the tension on the despooler. Is it set too tight or is the wire feed tension not set correctly?

  2. Are you using .035” wire? We recommend .030".

  3. Is your stickout too long? Your stickout should be no more than ½”. 

  4. Make sure you are pulling the trigger on the MIG gun to begin welding.

  5. Make sure the ground is not attached to painted or coated metal.

Try these troubleshooting fixes:

  1. Remove the battery and the piece of paper between the battery and electrical contacts.

  2. The helmet is in “grind” mode, which means it will not activate for welding.

  3. The shade or sensitivity is not set correctly.

  4. The battery is dead and needs to be replaced.

  5. The sensors are dirty or covered.