Big welding wire spools, little welders

[junya92toy]

So if you look around, sometimes you can find great deals on bulk products. I was looking online and found a brand of wire the local welding supply store has. Anchor brand, I called them up, 035 hard wire, 33 pound spool 82 bucks. I found the same but in a 44 pound spool for 74, free shipping.

So I decided to build a external wire holder for my miller 211.
I had everything but the bolt, washers and nut laying around.

Basic of the holder are, I used some plate for the base ,angle for the column, 2 inch round tube for the spindle misc flat bar and a small bolt for the pin, to keep the spool "attached" to the 2 inch tube and a spring. You want to do a slight angle to keep the spool from coming off.


The end and the spring used to put pressure on the spindle so it can not unwrap



Getting the wire into the welder, simple drill a hole, and you can see i used a gun liner I had laying around so it will feed nicely past the hole and not chafe.



I cut it just long enough to go into where the drive roll is.
It looks like I have 2 wires going into the drive roll, I dont, I just did a mock up of the second liner.



Next I made a small block to hold the liner in place, 2 magnets to hold it to the case, and a set screw


And thats it. Another perk to this setup is, you and keep a smaller roll of wire in the welder as well. I have .035 dualshield for when I need to do heavy welding. It is a gas shield flux core wire but it used the same polarity as hard wire.

[IronClad]

Nice! you did the hard work for me we talked about doing somthing like this a while ago, let me know how it works long term wise since i have 2 large spools of .035 sitting on a shelf for when i burn through this one.

[junya92toy]

I just finished it up tonight, I ran some beads and it welds like normal. I dont ever see anything that could be a issue with it.

[IronClad]

right on. i even have an old liner that is torn down by where it goes into the welder. might be able to salvage it to do the same thing

[Moit88RNR]

Nice work. I'll be doing this in the future 

[Sparkplug]

Nice!  10 lbs is enough for me but the price savings is definitely something for me to consider.

[Hezzy]

care to give out your website for where you found the wire?

[junya92toy]

Overstock . com anchor brand

[pumkin toy]

good job man, I did this to my Hobart 187 about a year ago.  I have never had a problem with it.  I save tons of money by using the 44 lb spools.  I buy mine through linweld here in Rapid City SD.  I use Viking brand wire. a 44lb spool of .035 hard wire only cost me 50 bucks.  Compared to spending 27 on a 10lb spool.  That's a savings of about 68 bucks every time I use up a 44 pounder!  Its worth it for sure to do this mod if you use your welder all the time.

[junya92toy]

Yes its a huge savings thats for sure. Getting free wire in a way haha. Only thing I would say is, I will be getting a wire cleaner for it since its exposed now. But its cheap to get them

[junya92toy]

Been running some wire with this setup, here is a vertical up. Works great so far

[HogCanyonHopper]

  nice job Jerry. that would work real sweet with my Hobart 140

[Hezzy]

Thanks!! this is an awesome project I hope to scratch off my list someday soon.

[MRHilux87]

Never thought of that but I just put my 3rd or 4th 10lb spool on this year and it sucks.  Did you build a rack on your welding cart for the bigger spool or do you just have a really long stinger?

[junya92toy]

The holder for the big spool is directly behind the welder or it wouldnt work