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  1. #16
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    Quote Originally Posted by snapatap View Post
    I have run heaps of fluxcore wire and never used knurled rollers. Never even heard of them before this thread.
    If your liner is clean and you have a reasonably straight gun cable you can run fluxcore with standard v groove rollers, but knurled are the correct ones for flux core. They are a very common item and easily available for reputable machines.

  2. #17
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    Aug 2009
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    Sydney, NSW, Australia
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    I think the only mig welder i have bought with that roller was a SIP welder, my Unimig Razor came second hand but new in the box it came with both sets of V rollers which seem to work with gasless, there was a bit of fluffing around with spool nut tension tho

  3. #18
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    Jan 2016
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    Gosford
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    In my opinion if a gasless welder is supplied without a knurled roller, it ain't a gasless welder. Just sayin'.
    Yes, you can do it but should you? You can run hollow wire through a V-groove roller but would you run Aluminum through it or would you use a U-groove (soft wire) roller?
    If you run hollow in V-groove, use a big tip. Electrical contact won't be as good but less chance of jamming up and jerky feed. This is what makes poor welds.

  4. #19
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    Aug 2009
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    Sydney, NSW, Australia
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    Glivo i use the V roller for anything i have ran gasless and aluminium thru it both worked, this was the Unimig Razor 200 with V roller on 8mm aluminium machine maxes out at 6mm but i tried it, Don't think i got into that spray form because of those little droplets along the weld
    Attached Images Attached Images

  5. #20
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    Jan 2016
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    Gazza, it can be done, and obviously you know what you're doing so all the easier. I can do it too, as can many others. But there are amateur welders out there, with no formal training, buying these low end machines and wondering why it isn't working for them. Hopefully this will help them realise it isn't anything they are doing wrong. Correct equipment makes a huge difference to workmanship.

    (Sorry, but that is my "old school Ind Arts" training coming through. Pride in workmanship used to be in the syllabus Aims and Objectives . All lost in the Design and Technology era of the 1990's and even further away now.)
    Ooops.

    You would be completely aware that tuning a Mig welder's reel brake tension and wire feed pressure to accomplish welds like your example is not unlike setting the drag on a game fishing reel. Too loose - you're spooled. Too tight - you're broken off. Just right, you eat fish. The difference between good wire feed and bad is tiny unless you know about it but the difference in weld quality is immense.

    You can cut veneered or melamine composite board with a sharp 24 tooth blade, with care and preparation, but using a 48 or 60 tooth blade will give better results and much easier.

  6. #21
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    Aug 2009
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    Sydney, NSW, Australia
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    Glivo i actually dont know much about mig welding i cannot weld steel for the life of me but my aluminium welds come out sort of ok, this was done with the steel liner and V roller just to test the machine i have done far better welds with a $300 machine so far both machines using the steel liner too

    i am justa rookie at mig welding i actually keep trying but i dont really like it i love Tig welding tho still need more practice

  7. #22
    Join Date
    Aug 2006
    Location
    Melbourne
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    1,105

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    A knurled roller will also block your liner up faster. I'd just try out the V groove roller before spending the $$$ on a knurled roller, if you don't have any feed issues i'd leave it as is.

  8. #23
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    Jan 2016
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    The Rossi is now sold so unless I get another it's all intellectual, however you raise an interesting topic for discussion. I would never hesitate to use the appropriate and recommended feed roller, if it is available, especially while the machine is under warranty.

    Sent from my SGP521 using Tapatalk

  9. #24
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    Jan 2016
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    Quote Originally Posted by Com_VC View Post
    A knurled roller will also block your liner up faster. I'd just try out the V groove roller before spending the $$$ on a knurled roller, if you don't have any feed issues i'd leave it as is.
    Would this only occur if you use a knurled roller on hard wire (copper coated) intended for V-groove? Or are you saying that using the correct machine part for hollow flux cored wire will lead to early liner clogging? This would be news to me but I don't doubt it's possible. The hard wire may chip from the knurl teeth where the hollow wire should be softer and have some give in it meaning less chipping. Maybe!! I'm not sure now.

    The way I see it is that you want wire to feed steadily at constant rate with the minimum functional tension settings on both the drum brake and wire feed. This prevents unnecessary and avoidable wear on the wire feed unit, which is not really considered a consumable part. Using a knurled roller is intended to allow that. If it does lead to liner clogging then this is able to be either cleared or replaced and the liner is considered to be a consumable, or at least a wearing service part.

    Anyhow, I told the guy who bought it he can go either way. Buy the knurled roller from eBay for $20 or use what he has with an O/S tip.

    The plus side for me is that I've obtained a new welder trolley and a D size bottle for less than half price.

  10. #25
    Join Date
    Sep 2011
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    Northern Beaches, Sydney
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    68
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    Quote Originally Posted by glivo View Post

    For anyone using these machines, or any other without any table of settings, I've used this site for quite a while. https://www.mig-welding.co.uk/calculator.htm Enter your machines minimum and maximum power output values (in this case 60 A and 185 A) and the number of power settings (in this case 10). The calculator then generates tables which give a good starting point to set your controls to based on wire diameter and metal thickness. A little tweaking and your away. A good thing to do is to measure your wire feed output in meters / minute as well as this will help you use the tables generated by the calculator.
    glivo, that is a very handy calculator.
    I just used it to work out a few things. Too easy.

    Stewie

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