MIG Aluminum Weld without using Portable Spool Gun? Yes it’s Possible!

by Ashish Kumar Consultants

Heard about MIG welding aluminum without a portable spool gun? Thinking of giving it a try? Well, it is quite understood that spool guns are expensive and come with several drawbacks.

Undoubtedly, aluminum welding is quite tricky even if you are using a $250 spool gun. But if you are up for the challenge and have a little patience, this webcast has come up with tips and techniques to utilize your welder to MIG weld aluminum without a portable spool gun. And you will come to know how one of the most popular 120-volt hobby welding machines does on aluminum straight out of the box-without using a spool gun.

An Expensive Accessory

Most of do it yourself welders, sooner or later, need to tackle an aluminum welding project. The primary job is usually a minor repair or customization to a vehicle or something around the house. For a one-time job, you might not want to spend extra money on a spool gun. New spool guns cost half as much as many hobbyists spend on a welder. And not all MIG welders can support a spool gun- so using one may not even be an option.

Successful welding with aluminum needs a stable arc. With its short feed distance, a spool gun provides a steady and reliable feed of the soft aluminum wire.

As an alternative to a spool gun, it may be possible for you to adjust your MIG welder so that it can provide a steady, reliable feed of wire to the weld. Soo if you ca pull this off and if your welder has the power required, there is no reason you cannot weld aluminum without a portable spool gun.

What are the Drawbacks to the Spool Guns?

Apart from its high cost, there are many other disadvantages of using a portable spool gun. Spool guns are heavy and bulky, so they are not at all ideal for faster travel speed required for aluminum welding, or to be used in tight quarters. Moreover, the capacity is limited to small and one-pound spools.

So, if you are working in close spaces, or larger projects, you might prefer using a smaller, lighter MIG torch led from a larger spool.

Reducing Friction to MIG weld Aluminum without a Spool Gun

It is obviously a delicate act of balancing. You would want to minimize the drive roller pressure on the wire to prevent squeezing and deforming the soft wire. The deformed wire will add friction and cause a hang-up.

On the contrary, you need enough roller pressure to maintain a smooth, consistent wire feed to the weld. Any slippage of the wire will cause the electrode o burn back to your contact tip, thus ruining it.