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How to Weld With a Spool Gun

In the world of metalworking, the metal inert gas welder is king. This welding system incorporates a wire feeder that pushes a length of welding wire from the main unit through a cable, and out the tip of the hand held gun onto the metal surface being welded. Aluminum wire, for welding aluminum surfaces together, is too pliable to be fed through the system without bending or kinking. It is for this reason that the spool gun was created, incorporating an aluminum wire spool into the gun itself.

Things You'll Need

MIG welder
Spool gun
Argon gas cylinder

Instructions

- 1
  Connect the welding cable from the spool gun to the positive terminal in the welding machine.
- 2
  Straighten a length of aluminum wire from the spool and insert it through the gun, from the rear of the spool housing through the guides and out the tip. Close the tension arm over the wire, replace the cover over the tension arm and then screw on a contact tip that matches the gauge of aluminum wire you are using, followed by the welded nozzle tip.
- 3
  Clean the surfaces of the aluminum you wish to weld using a stainless steel wire brush and clamp them together in the orientation you would like to weld them permanently. Welding aluminum sheet of less than 14 gauge will most likely result in a burn through, so stick to thicker gauges.
- 4
  Place the tip of the welding nozzle about 3/4 inch away from the surface of the aluminum at an angle of about 70 degrees. Then push the trigger and lay down a bead of weld. It is best practice with aluminum welding to push your weld rather than to pull it. There should be a hissing sound rather than the typical "bacon frying" sound of steel welding. If you are having problems with spattering of aluminum, or excessive smoke, adjust the voltage output on your welder until you achieve satisfactory beads.

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