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TDmaker01
04-11-2010, 12:17 PM
Hi, I bought a 450 amp mig welder some months ago for a steal and have not had it going yet. I needed a couple parts which I have bought but have not installed yet. The rollers in the external wire feeder are for .045" wire. New Rollers for .035" wire are just shy of $200. The rollers have 3 holes though them to be mounted to the gears that are turned by the motor. I have heard of tigging old worn out rollers and re machining them to like new again. My question is, what material would you use to make a whole new set of rollers? I would like to keep the .045 rollers for heavy work but want .035 for general purpose. Would a bit of HRS stock suffice? or should I use a lower carbon steel. Should they be hardened? Thanks

wierdscience
04-11-2010, 12:21 PM
1045,4140,8620,O-1 etc will work fine for rollers,hardened would be better.You could use hot rolled also,just look up case hardening or carbon pack hardening.

sal64
04-11-2010, 12:27 PM
you could use drillrod but not as good as hardend.

TDmaker01
04-11-2010, 12:52 PM
Thanks alot! I will start to grind up a tool bit momentarily and find a hunk of 01! thanks

CCWKen
04-11-2010, 01:47 PM
Did you look closely at the roller? Mine are reversible for different wire sizes. If they're not, something to think about if you're going to make some.

KINGWELD
04-11-2010, 02:37 PM
Howabout a picture of your drive rools? What make machine do you have?? Let me know as I might be able to point you I the right direction for drive rolls.

John Stevenson
04-11-2010, 02:47 PM
Are they solid rollers, some have insulated bores.

Black_Moons
04-11-2010, 03:02 PM
Gez, new rollers for my chinese crapwelder are like, $20~40?
Depending on diamiter you might just be able to change the bore on cheaper wheels.

macona
04-11-2010, 04:47 PM
Something is wrong there, I have never seen a set of rolls go for $200. What kind of machine do you have?

MrSleepy
04-11-2010, 05:00 PM
Something is wrong there, I have never seen a set of rolls go for $200. What kind of machine do you have?

Sounds about right for a set of ESAB rollers (but they are hand made by virgins out of steel plated gold)


If they cant be bought reasonably..then Id have a go a turning them down and sleaving them
If the rollers have the gears machined on to the you'd still be able to turn and sleave.
I had to do that for my Norman Butters on an old set of rollers to run some ally wire.

Rob

TDmaker01
04-11-2010, 09:59 PM
Did you look closely at the roller? Mine are reversible for different wire sizes. If they're not, something to think about if you're going to make some.

The rollers on it are reversable however they are for the same diameter wire. It is a Canox (made by miller) and is 28years old. Ive called Unitec, BOC and Air Liquide two of them wanted $188 (there is 4 rollers needed) and one was $194. Ive made my tooling, but could not find a piece of 4140 or O1 big enough at home so tomorrow I will look in the ends bin at work for somthing, I dont have a digital camera so, sorry no pictures. and no, they are not insulated cores

macona
04-11-2010, 10:18 PM
I think that consists of a kit to adapt it to use modern drive rolls which are a lot cheaper. I have had to install them on some older feeders.

dvbydt
04-12-2010, 05:15 AM
I made a few drive rolls to fit Kemppi and Lincoln a long time ago. The groove was 15 degree inclusive and the trick is to drive on the sides of the groove not on the bottom. They were case hardened and the bore honed after heat treatment.

IanR

MuellerNick
04-12-2010, 06:21 AM
and the trick is to drive on the sides of the groove not on the bottom.

This is true for steel wire, but aluminium requires a U-shape.


Nick

dvbydt
04-12-2010, 07:10 AM
Nick,

I had a lot of aluminium channel to weld up and had no luck at all trying to drive wire up 3M of torch. Didn't matter what rolls or liners, they always gave trouble. The solution was an old Miller spool on gun torch, it worked forever without any problems.

IanR

MuellerNick
04-12-2010, 07:18 AM
I do have a 4 roll drive and i slightly modified the inlet into the liner. Works with 1mm Al wire and the right liner.


Nick

phatfred8
04-12-2010, 12:46 PM
I would call Stumpf Welding Supply (618-5664733). They ship UPS and the standard Miller drive rolls used on most of the industrial equipment will work. You can get aftermarker rolls for Profax(they carry these) for about $50 dollars. Hardened, (4) drive rolls and guide tubes.

Talk to Kevin or Jared.

I worked there for many years. You could also look up Profax online

BM

snowman
04-12-2010, 01:24 PM
Listen to Macona. Post the specifics of the machine and he's awesome help.