Step 9: Wire Fuses to Tip/Change the Tip

Sometimes if you are welding too close to your material or you are building up too much heat the tip of the wire can actually weld itself onto the tip of your welding gun. This looks like a little blob of metal at the tip of your gun and you'll know when you have this problem because the wire won't come out of the gun anymore. Fixing this is pretty simple if you just pull on the blob with a set of pliers. See photos 1 and 2 for visuals.

If you really scorch the tip of your gun and fuse the hole closed with metal then you need to turn the welder off and replace the tip. Follow the steps and the overly detailed photo series below to see how it's done. (It's digital so I tend to take too many pictures).

1. (Photo 3) - The tip is fused closed.

2. (Photo 4) - Unscrew the welding shield cup.

3. (Photo 5) - Unscrew the bad welding tip.

4. (Photo 6) - Slide a new tip into place.

5. (Photo 7) - Screw the new tip on.

6. (Photo 8) - Replace the welding cup.

7. (Photo 9) - It's now good as new.
Spudmuffon2 years ago
Except for all the splatter on the nozzle clean that up I would rather knock it out with a round file but a screw driver, small pry bar, scribe, pliers will work.
amoroso825 years ago
I recently found the need to get a MIG welder to do some repairs around here, since I have never used this meathod of welding before I got a book and began to read up on this. Now I saw this article in Instructables that has raised some questions.
 I purchaced an 120 amp welder from Harbor freight as I am not going to use this machine to do structural welding I got their middle one. ( there is one cheaper and one more expensive) I guess since I was buying crap I didnt want cheap crap.  Any way they said that there is no need to use an external source of inert gas even though the machine is set up for it, I was told that I could use wire that has flux or some material that produced inert Gas while you are welding. Is that an inferior way to weld?and do I need to get this bottle?
 The reason I asked this is because I have read almost through this whole article and the writer has only mentioned the flux core wire once. I got this thing because it was less expensive than a buzz box and I can weld thin metals easier but if I have to shell out more spondulix for gas bottles and gauges the price can go up dramaticly.
Technically speaking alot of Flux cored wires produce better quality welds than solid wires do. They do have drastically different techniques though.

flux cored wires require longer electrode stick outs and faster travel speeds. Also, you'll need to use a slight drag angle instead of pushing.
I started to learn to weld a week ago and those mig pliers bentherkahn was talking about are great! BUT i have one concern. they arnt balanced meaning they constanly fall of the table or rack, the grip is awesome when using thick gloves but the grip makes it difficult to stuff in my back pocket.The pliers are hard to pickup off a table.  I got the same pliers, perfect for removing the nozzle, tips, and it per-measured to cut the wire and leave exactly 1/2" wire.  I use welding dip, i dip it every twenty-five welds or so usually everyother day welding for 10minutes a day practicing.
tenfingers5 years ago
I've sometimes been sucessfull reusing a burned back tip by filing or grinding down the tip to free the wire.
scott585 years ago
 We use a container of petroleum jelly at work. After you welder is hot just dip the tip and it helps allot with build-up,
benthekahn6 years ago
It seems like there is a lot of build up on the cup in these pictures. I found these MIG pliers help a lot.
tzhauling6 years ago
A tip to avoid spatter from sticking from the tip it to dip the tip into liquid flux before welding, and a few time during welding if welding for a long period.