Producing a clean, solid, strong weld requires that your welder feed the wire consistently and at a proper speed. If your small MIG welder has started to stutter, you'll be left with a pitted, uneven, and potentially weak weld. The good news is that you don't necessarily have to buy a new feed gun or even a new welder in this case. Most times, you can take the feed gun apart and fix the problem. This is what you need to know to do it.
Cut The Power
Unplug the welder before you do any kind of work to it. That means not only unplugging it from the wall outlet, but also disconnecting it from any power generator you may have it connected to. The last thing you need is to have the welder inadvertently start when you're working on it.
Disassemble The Feed Gun Handle
When you look at the handle of the feed gun, there are round collars on either end. Unscrew those collars to take the handle apart. Some of the collars require only a quarter-turn, then they pull loose. Others are traditional screw-style collars that must be completely unscrewed. It will depend on your feed gun model.
Use your hands to loosen the collars. Don't try to use pliers on them, because they're plastic and you'll risk damaging them. Similarly, you want to avoid using any kind of lubricant. It'll interfere with the metal-to-metal contact required for the feed gun to work right. After you remove the collars, you can separate the handle into two pieces. It should separate in the middle. Be prepared for the trigger spring to come out when you open it, and don't lose that spring.
Check The Contacts
Now that you have the handle apart, look at the contacts inside. Make sure that they are all seated properly. If they're not, the connections will be intermittent. That will cause the stuttering response. Push them gently back into place so that you get proper contact between them when the feed gun is running.
Reassemble The Handle
Put the trigger back in place so that it sits flat in its spot. You'll want to hold a finger on it since it's got some spring to it. Then, close the two pieces of the handle so that they snap back together. Replace the two collars on either end, ensuring that they lock into place.
If this doesn't fix the stuttering problem, you'll want to talk with a local welder repair technician about what else could be causing the issue. For more information, contact companies like Vern Lewis Welding Supply Inc.
