Welding 3/16" & 1/4" with 120v wire-feed

haveissues · Jun 25, 2014

Sodo said:
Currently there seems to be a gag-order on helping anybody to use a 120v MIG, so it might be awhile but I'm trying to wear these guys down. They WANT to help, but can't seem to get over (under) that "120v problem" at the moment.

I for one am glad this conspiracy is out in the open. Are we going with the lone Millermatic theory or do we thing there could have been a Powermig on the grassy knoll? With any luck this will make it on the history channel in between episodes of ancient aliens and the hunt for the loch ness monster.

Sodo · Jun 25, 2014

aczlan said:
The problem is that you are being disagreeable and looking for ways to argue.

Aaron you could be right, but nobody seems to have been successful in the past (IMHO). You too, sir seem to be unaware to know that you have a GREAT machine (IIRC, a Miller 211?) that can do the project you started, VERY VERY well. I suspect even on 120v, but not sure I can't tell what thickness that material is.

aczlan said:
View attachment 380615
It had all it wanted to do to weld this and I tripped the 20 amp breaker at least once welding this on.
Aaron Z

Strange, I use a couple 120v generators that has a 20A breaker, and it has never tripped. The welder is a Miller MultiMatic 200. I think it's similar in capability to a 211. The MultiMatic 200 runs on either 120 or 220. I have a 220v generator (5kW) but it's only 10HP so it can only weld to 1/4". I'm not inspired to use it because it doesn't add much and you can hear it in 3 counties whereas the Hondas are easy to carry and pleasant sounding. If I run the MM200 on the 5/16" preset, it pulls the 10hp generator down. So there you have a (non-expert) data-point on how much horsepower it may require to weld 1/4". I am on the lookout for a 15HP generator.

Here is an example project welding 1/8 sq tube to 3/16 plate with 2 Hondas on 120v. I am replacing an old used-up trailer jack with a new, larger unit. This weld was done with the machine (on 120v) and set on 3/16" thickness, with .030 wire, 75/25 AR/CO2. Then I reduced the wire speed a little based on a comment that Shield Arc slipped out (oops

). This weld was done yesterday.

aczlan · Jun 25, 2014

Sodo said:
Aaron you could be right, but nobody seems to have been successful in the past (IMHO). You too, sir seem to be unaware to know that you have a GREAT machine (IIRC, a Miller 211?) that can do the project you started, VERY VERY well. I suspect even on 120v, but not sure I can't tell what thickness that material is.

Both sides of the metal were 3/16ths steel. As for the Miller 211, I love to use it and its a great machine, however its not my welder, it belongs to my neighbor. He is happy to let me use it anytime he is available (and wont even let me pay him for consumables), but he is a busy guy and I dont want to impose on him.

Sodo said:
Strange, I use a couple 120v generators that has a 20A breaker, and it has never tripped. Here is an example welding 1/8 sq tube to 3/16 plate. The welder is a Miller MultiMatic 200. It runs on 120 or 220. I have a 220v generator but it's only 10HP so it can only weld to 1/4" and I'm not inspired to use it because you can hear it in 3 counties.

It was in the neighbors shop which is wired with 12/2 and 20 amp breakers. Not sure if the breaker is weak (although the Miller trips it less than the Craftsman MIG that it replaced) or what, but the 211 was turned all the way up to weld that plate to the tube.

Aaron Z

Sodo · Jun 25, 2014

Hmmmmm I would have expected that 211 should be able to make a nice weld on 3/16" on 120v. But I have zero experience with the 211 so there ya go. I would like to try a 211 someday to prove to myself. I went into AirGas to buy a 211 but walked out with a MultiMatic 200 due to the craftiness of a salesman (who asked what I wanted to do with it and then pushed all my buttons). The MM200 is doing what I want, I'm pretty happy with it, the portability is great for my usage.

aczlan · Jun 25, 2014

Sodo said:
Hmmmmm I would have expected that 211 should be able to make a nice weld on 3/16" on 120v. But I have zero experience with the 211 so there ya go. I would like to try a 211 someday to prove to myself. I went into AirGas to buy a 211 but walked out with a MultiMatic 200 due to the craftiness of a salesman (who asked what I wanted to do with it and then pushed all my buttons). The MM200 is doing what I want, I'm pretty happy with it, the portability is great for my usage.

It made a nice weld, but I wouldn't want to go much thicker than that in 120v mode. Miller says that it will do 1/4" on 120v (page 9: http://www.millerwelds.com/pdf/MMMBG.pdf) but (IMO) you would have to be good to make it work.

Aaron Z

Reverser · Jun 25, 2014

dragoneggs said:
My new shop is still jerry-rigged for 230v (old dryer outlet with a modified extension cord from costco). Not proud, but until I get it right, it powers my tablesaw, air compressor, and welder.

Been there, done that. :thumbsup:
The worse case scenerio (and sometimes dangerous) with that set-up is to have to tell the missus on laundry day that she's going to need to wait on drying the clothes until you get your welding project done. :laughing:

Reverser · Jun 25, 2014

Sodo said:
Here is an example project welding 1/8 sq tube to 3/16 plate with 2 Hondas on 120v. I am replacing an old used-up trailer jack with a new, larger unit. This weld was done with the machine (on 120v) and set on 3/16" thickness, with .030 wire, 75/25 AR/CO2. Then I reduced the wire speed a little based on a comment that Shield Arc slipped out (oops ). This weld was done yesterday.

View attachment 380627

View attachment 380626 View attachment 380624 View attachment 380625

Sodo, be careful!! You're getting awfully close to getting PRO status.

Then Arc Weld will be forced to start admiring your projects instead of criticizing them.

Sodo · Jul 1, 2014

I doubt that Arc Weld would consider the whole project or servicability. I bet he would conclude the whole project is failed by the porosity that I covered over.

I just join the metal to get the strength req'd and move on. I can't do that all day long (like a pro). These worked out to look nice because hand positions were perfect, wind didn't gust much and some other etc etc such as the intent to post a simple 120v project on TBN. I would like to have the skill and time to get that finish consistently and who wouldn't?

trihounds · Jul 1, 2014

Couldn't delete double post

trihounds · Jul 1, 2014

Sodo said:
......... Strange, I use a couple 120v generators that has a 20A breaker, and it has never tripped. The welder is a Miller MultiMatic 200. I think it's similar in capability to a 211. The MultiMatic 200 runs on either 120 or 220. I have a 220v generator (5kW) but it's only 10HP so it can only weld to 1/4". I'm not inspired to use it because it doesn't add much and you can hear it in 3 counties whereas the Hondas are easy to carry and pleasant sounding. If I run the MM200 on the 5/16" preset, it pulls the 10hp generator down. So there you have a (non-expert) data-point on how much horsepower it may require to weld 1/4". I am on the lookout for a 15HP generator. Here is an example project welding 1/8 sq tube to 3/16 plate with 2 Hondas on 120v. I am replacing an old used-up trailer jack with a new, larger unit. This weld was done with the machine (on 120v) and set on 3/16" thickness, with .030 wire, 75/25 AR/CO2. Then I reduced the wire speed a little based on a comment that Shield Arc slipped out (oops ). This weld was done yesterday. <img src="http://www.tractorbynet.com/forums/files/welding/380627-welding-3-16-1-4-a-img_8223-jpg"/> <img src="http://www.tractorbynet.com/forums/files/welding/380626-welding-3-16-1-4-a-img_8218-jpg"/><img src="http://www.tractorbynet.com/forums/files/welding/380624-welding-3-16-1-4-a-img_8215-jpg"/><img src="http://www.tractorbynet.com/forums/files/welding/380625-welding-3-16-1-4-a-img_8217-jpg"/>

I'm really glad you posted this because I've been wondering about generator use and welding, and why I couldn't use my continuous 7K to run a welder, wherever 220 isn't economical or practical. How come we never hear about people using gennies to run a larger welder? Is it just the noise and inconvenience factor?

These have been great threads on welding and I appreciate the input from both weekend welders and pros. Thanks for starting them.