# of FAQ's Filtered:

Forney ITEM# 85263 would be a suitable replacement. To order this product, you'll need to contact our Customer Service team. 

Forney ITEM# 84909 would be a suitable replacement. To order this product, you'll need to contact our Customer Service team. 

Welding on cast iron requires the part to be preheated. 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. See our entire line of cast iron electrodes here: https://www.forneyind.com/products/welding/stick/stick-electrodes?L4=cast+iron+electrodes

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. 

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. Without any of this information, we can't make a solid recommendation. You may want to refer to the product descriptions found in our line of electrodes: https://www.forneyind.com/products/welding/stick/stick-electrodes

Unfortunately, both models you're referring to are discontinued. However, you can use a generator with these Forney welding machines:

  • 140 MIG minimum generator power required is 6 KW
  • 190 MIG minimum generator power required is 8 KW
  • 210 MIG minimum generator power required is 9 KW
  • 270 MIG minimum generator power required is 13 KW
  • 140 MP minimum generator power required is 6 KW
  • 190 MP minimum generator power required is 8 KW

Forney 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.

Unfortunately, that item was discontinued. You may be interested in some of our newer machines.

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.

Unfortunately, that machine has been discontinued. You can see our current line of MIG welders here: https://www.forneyind.com/products/welding/mig/mig-machines

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

  • off off
  • off on
  • on off
  • on on

We offer two 4-packs of contact tips:

We also offer an ITEM# 85316 shield gas nozzle.

Yes, Forney ITEM# 60165. It comes as a 3-pack.

You may find this document useful: https://www.askforney.com/files/8714/1107/6686/Spitfire-Sl225-Welder-Manual-And-Schematics.pdf 

  • ALUMINUM: For welding aluminum, an aluminum wire will be required as well as gas. Argon will need to be used in this application.
  • STAINLESS STEEL: For stainless steel, likewise a stainless wire will be required. You can use either argon or CO2 on this wire.
  • MILD STEEL: 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 Fahrenheit 
  • Use short welds
  • Peen immediately after welding
  • Grind any 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 
  • Packard, Inc. (800) 334-1769

Yes, ITEM# 85359 will fit the Clarke WE6540 regulator. To order this product, you'll need to contact our Customer Service team. 

If the regulator and barb were Forney products, we do have an adapter, ITEM# 85359 that will work for the connection. It's a quick connect device that the gas line goes inside of. To order this product, you'll need to contact our Customer Service team. 

Yes, the warranty will still apply. The warranty for the welders is 5 years on the transformer, 3 years on the rest of the internal components, and 1 year on the MIG gun, relays, contactors, regulators and accessories. You can see full warranty information here: https://www.forneyind.com/support/warranty-information

Unfortunately, we don't have schematics for the Clarke 190EN welder to confirm or not the 180FI gun will work. We sell these as a torch and gun assembly under our ITEM# 85263 if you'd like to give it a try. To order this product, you'll need to contact our Customer Service team. 

We do have parts available that would work:

Depending on the spool size you're looking for, we have the following available:

Here's the product description: 

ER70S-6 mild steel MIG welding wire is a high strength mild steel MIG wire. Ideal for auto body repair and fabrication on most ferrous metals. Contains a high level of manganese and silicon for a superior weld, even on rusty, dirty steel. Produces a smooth bead which requires less grinding. Not recommended for aluminum engines. Yellow color coding on label.

  • Required Shielding Gas: Argon/CO2
  • Recommended Polarity: DCEP Reverse Polarity
  • Diameter (Inches): .024
  • Tensile Strength (PSI): 70,000

Unfortunately we do not offer a spool gun for this machine.

Unfortunately this machine has been discontinued and we no longer carry these parts. You can contact L.B.L., Inc, 700 E. Elm Avenue - Unit B, La Grange IL, 60525. Their number is 708-579-5893.

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 (contact our Customer Service team to order).

Unfortunately we don't carry parts for these welders available any longer. We recommend checking with a local electrical supply shop.

Yes, you can find it here: https://www.forneyind.com/products/er4043-035-x-1-lb--aluminum-mig-welding-wire 

Here is the product description:

ER4043 aluminum MIG (GMAW) welding wire features 5% silicon content and a bright finish. Flows freely at 1,155° F (624° C). Works well with spool guns. For truck bodies, pressure vessels and structural members. Dark gray color coding on label.

  • Required Shielding Gas: Argon
  • Recommended Polarity: DCEP Reverse
  • Diameter (Inches): .035
  • Weight Lbs. (Kg): 1 (.453)
  • Tensile Strength (PSI): 33,000

Forney Industries offers nationwide welding machine service through more than 150 independent Warranty Service Centers.  If you are having trouble with a product and need technical troubleshooting assistance, please call 970-472-7056 or visit a Warranty Service Center location near you

Forney ITEM #318 (190 MIG Welder) and ITEM# 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. 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 pass:

  • 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 to 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.

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. 

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

As for 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. 

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 and easy.

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.

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.

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

The Forney 250P+ (ITEM# 317) does not have a problem with dry air.  We've actually added driers to the newer models as 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 even a stainless steel arc rod.

That sounds like a problem with the rectifier. MIG machines 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. Check out 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 - ITEM# 84994. To order this product, you'll need to contact our Customer Service team. 

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 level machines have an 8' and 190 level machines on up have a 15'.

Tweco #2.

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

No a .035" wire is the maximum size the 140 MIG can handle; 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 a larger diameter tip.  

Also use a larger diameter wire like .035" or even .045" so it's stiffer and easier to push.  Remember that a spool gun works best.

It depends on how thick the material is that needs 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 than 200A, go with .030”.

Start at the despooler and work forward. Check the following:

  • Correct wire size
  • Cleanliness of wire
  • Despooler tension
  • Drive tension adjustment
  • Drive roll size
  • Guide tube alignment
  • Any burr on liner
  • Correct liner size
  • Cleanliness of liner
  • Tip size correct

If you're still having issues, call our Technical Support line at (970) 472-7056 for further assistance.

Check for:

  • Are there any leaks?
  • Using the right 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 flux core, 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 could be set too high for the specific voltage you are at.  Give us a call at (970) 472-7056 to speak with a Technical Service technician to discuss your settings and diameter.

Gas isn¹t required for Forney ITEM# 42300, although you may use gas if you¹d like.

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

The machine can use .035” but it doesn’t do well with that diameter.  We recommend no larger than .030”.

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 but we 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.  We 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: We 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: We 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, we would recommend ER70S-6 MIG wire with a 90/10 shielding gas. For steel stick electrodes, we 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.

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 Forney ITEM# 85363 regulator is compatible with Hobart welders.

You can use the following contact tips depending on the size of wire you're using: 

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

Excerpt from a Technical Bulletin: 

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. 

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

Unfortunately, Forney Industries doesn’t offer a TIG torch with a fingertip control. 

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 (ITEM# 299) 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.  

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. 
  • 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:

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

Here are a couple of common issues:

  • Check the tension on the despooler. Is it set too tight or is the wire feed tension not set correctly?
  • Are you using .035” wire? We recommend .030".
  • Is your stickout too long? Your stickout should be no more than ½”. 
  • Make sure you are pulling the trigger on the MIG gun to begin welding.
  • Make sure the ground is not attached to painted or coated metal.

Try these troubleshooting fixes:

  • Remove the battery and the piece of paper between the battery and electrical contacts.
  • The helmet is in “grind” mode, which means it will not activate for welding.
  • The shade or sensitivity is not set correctly.
  • The battery is dead and needs to be replaced.
  • The sensors are dirty or covered.

80 Amps at 20%.

This welder requires a minimum 3500-watt generator to operate properly.

This machine should be fine to run on a surge protected outlet. You will want to make sure the rating for current on the surge protection outlet is at least 25 amps for this machine or it could damage the surge protector (depending on the type of surge protector).

We recommend Forney ITEM# 42298, ER308L, .030" x 2 lbs. Stainless Steel MIG Welding Wire. 

No, stainless steel requires gas to weld. The 125 FC (Flux-Core) does not use gas. We recommend Forney MIG machines for welding stainless steel.