Welding Aluminum with a MIG spool gun for the first time EVER

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Welding Aluminum with a MIG spool gun for the first time EVER. I bought the Millermatic 211 and the spoolmate 100 spoolgun with dreams of building diamondplate tool boxes, wakeboarding towers and dreams of sugar plums dancing in my head. However, with such high expectations and aspirations comes a fear of failure. I've waited a long time before even making an attempt because of this fear to fail. With a day off due to the 4th of July holiday and motivated by Jody from weldingtipsandtricks.com I thought I'd take an opportunity to practice laying beads on a piece of scrap alluminum I've had laying around the back 40 for the the last 7-8 years. As it turns out, old aluminum that's very oxidized and weathered creates a lot of soot and dross as you see in the video. It did make for some good practice for tip angle, stick out, and heat. Aluminum is expensive and you don't want to learn lessons on warping and cracking on something you've put a lot of time and money into.

[@Toadydo]

I like your down to earth honesty and no pretense in this video. Well done !

[@BigBoxDodge2020]

I've got the exact same set up as you do, and my first time Welding Aluminum with minimal practice. Years ago I made 1/8 inch thick, one inch wide Bows to cover my aluminum fishing boat and they turned out excellent. Today, I'm attempting to weld 1/16" angle to a thick block of aluminum. So I watched your video, to remind me & get tips from your commenters.

[@briansmobile1]

That is awesome!

[@brsha8762]

Excellent video...because it's REAL! I think you've done a great job of showing people that not only is it OK to make mistakes..but with skills such as welding, it's the ONLY way you actually perfect your craft! Very well done...and you made it easier for others to dive right in! So thank you

[@MrWillieZ]

you got it right welding is all about practice and if you don't make mistakes you don't learn

[@oldmill322]

Good job, it's nice to watch a regular guy trying something new and learning as you go. Thank you for the getting started video

[@joeanon5788]

My initiation with aluminum spool gun welding taught me that preparation was key, to include preheat to 300 Farenheight, 30 CFH argon gas, correct stick out (3/4"), 5 degrees work angle, and as usual, watch and control the puddle. The puddle is not as easy to see. It should appear as a silvery molten pool. Overheating the material will cause a weird wrinkling of the weld. Also wire speed and voltage take some tweaking. Typically the voltage is upped compared to a steel weld. The blackening is probably due to either/or low CFH, and white oxide on base metal. It is a "humbling" process. I would actually defer someone to learn TIG and /or use Alumiloy, Alumiweld braze rod with propane. Good luck (skill) my friend.

[@NordicDan]

Been using a MM211 for a few years now. Absolutely love it. When I first started welding it was a great beginners' unit, and now that I actually know what I'm doing I'm still more than happy with the unit.

[@kenengelhard7851]

I just got my Miller 211&100 spoolgun. Watching you was educational and comforting as I made all the same mistakes plus more. Hope you give more lessons on aluminum welding with the 100 as you improve your skill. Thanks, Ken

[@dancushing5399]

Thanks man... I REALLY appreciate you putting this video up , and sharing your experience , it was a big help to me !!

[@davidarnds3831]

I have seen some of your other videos and your training is great. It's like being with your brother. Very personal and humble and I enjoy listening to the on the fly play-by-play comments. Thank You!

[@johndough2779]

Thank you for posting this,,and thanx for giving Jody a "thumbs up". I'm 59 years old and I used to think I was a weldor until I found Jody's site a few years ago and, like you, I have learned so much from that guy. Anyway I love seeing young folks trying and learning and going unafraid,,challenging themselves. You are the future and God bless

[@Raphburger]

Excellent demeanor. Love the trial and error on display, a stroke of genuine genius. Keep up the pioneering work!

[@briansmobile1]

He's a good teacher and gives good pertinent, prudent advice.

[@codyguynn6386]

I'm reading all these comments, it's actually funny because everyone of us that can charge for welds had to go through the same thing as this guy at one point before we realized Tig welding was an art that needed to be mastered. we just didn't post our embarrassing moments on you tube. I give this guy kudos. hopefully you're stacking dimes with tungsten now buddy

[@jesseblanquel9233]

Cody Guynn ....veey good constructive commitment not like ones these idiots posted.... !

[@jeremyc9229]

Polite, and total sense, well said!

[@d.slater3958]

the first accessory I purchased when I bought my mts250s was a spool gun. Great tool and opens up the potential for aluminum welding. Nice video.

[@briansmobile1]

That's awesome- great to have you along!

[@briansmobile1]

Thank you- and thanks for the encouragement!

[@francismcclinchey8343]

Great video - very much exactly what I’ve been going through. Your perseverance and experimental approach are refreshing. Thank you.

[@briansmobile1]

Thanks for the tips- I figured out the tip cut and rewind, but cleaning the back side I needed to know that- you the man!

[@tsstn]

Thanks for putting this video up. I have two things I could offer. Number one, if you use .030 wire use a .035 tip if you use .035 wire drill the tip a little bit larger. I have used 1/16 inch drill bits to enlarge the tip orifice when using 0.035. Using an oversized orifice prevents the sticking which happens when the aluminum wire heats up back into the tip and expands locking it in place. I had very little trouble melting tips once I did this. This modification actually allowed the spray transfer to function, something I never achieved previously. Also don't make such big adjustments, you went from 60 to 70 on your wire speed, try smaller increments, with aluminum especially. I mean what I say when I say thanks for putting this up, it is a common problem with this setup which is exactly the same as mine. You may have gone on to the millerwelds forums and found that many people modify the barrel to use the larger size tips. It involves Drilling and tapping and not everyone has access to that but it is my plan as the next modification. Best of luck to you my friend.

[@oxygen454]

Did you have to reverse the polarity on the welder to weld aluminum? (Positive to negative and negative to positive)

[@neilrogers232]

Much respect for doing a video as first time use. I enjoy videos that show honest mistakes and errors. I have absolutely no knowledge of welding. I was looking into aluminum brazing and this video was a suggested. Great video my good sir. Thank you.

[@briansmobile1]

I have a pretty healthy self esteem. I'm in it for the learning/teaching opportunities. Thanks Dave!

[@geedubb2005]

thanks for sharing! I have a 180 and have alsways been curious about alum welding and like you, never had an ounce of education in it. Your presentation helps and I know I can do it too now! I love your attitude!

[@briansmobile1]

Welcome- great to hear from you!

[@richardcampossr3872]

On aluminum when starting a weld, I drag the wire back (about a inch or so) as i'm striking a weld this helps to preheat,if there is a gap it kind of fills it, if its old alum. that you are welding you will be laying fresh clean material on top to run your weld over it.

[@briansmobile1]

You're welcome- TIG is the way to go for so many things. It just gives you SO much more control..... once you've practiced.

[@nutgone100]

Great video, love it! We're not all professionals, we all have to learn some time, I'm just picking up welding again after very briefly learning it when I left school (about 16 years ago). This is the best way to learn, just pick it up & give it a go. Keep it up.

[@777Jesuswins]

I have the same welder you do. Todays my first time setting up my aluminum gun to. This has been great to see and get your learning curve in my head before trying to figure it out. Great video and a gold mine of easy first steps. Thanks for sharing. Awesome.

[@markstevansen542]

I got my everlast spool gun set up just last week. I can't wait to give it a try and see how I do!

[@777Jesuswins]

Like you I have been welding for years. But never aluminum. Your video gave me the confidence I needed to get everything changed over and give it a try. I found that at first I was making big dog turd puddles and had to get the flow figured out. Aluminum goes fast. I decided to get myself one of those 4 and a half inch grinding stones for aluminum to put on my grinder. Good choice. I was able to clean up my welds easy and then go back and do fill ins on hollow spots. Then grind them out and make the welds look smooth. My first job came out great. I mounted new brackets onto my old aluminum light frame that wraps around my windshield on my Jeep. I cut off the old mounts for 7 inch round spot lights and welded on new mounts that fit my 50 inch led light bar on the bottom side of the pipe. Now I am confident enough to make myself a roof rack for my hard top. Thanks for the little kick in the butt. They say a swift kick in the butt is a giant step forward. :) Thanks for the vid. Keep up the good work.

[@briansmobile1]

You're welcome - and thanks for the feedback!

[@carlosextromolo3753]

I'm thinking about getting a spool gun for my everlast mig welder. Thanks for showing your first attempts at welding with yours.

[@ovalwingnut]

Thank you for taking the time to video your "first time" :) As long as I can remember I've wanted to find a way to "stick aluminum together". Something that you generally can't do with a MIG, STICK or GAS (well, gas welding alum... a learned art!). A spOOLgun was one of the other possibilities. The other of course are TigWelder$, Kaching!. I know that your L-Curve may have ruffled "experienced welders".. But I think you were a fantastic stand in for the rest of us [shade tree welders] who were thinking of buying one too. I have no doubt I would have mirrored everything the same. Even down to the ground connection (what am I saying, I still do :). Cheers!

[@dalltex]

Thanks for the video! It's great to watch someone else learning. It makes me feel like crap when a master shows you how and then it's your turn and it doesn't work out the same. You have a great attitude and I'm sure by now you have it down.

[@bolee5256]

i like his style.....i like his humility.....and i like the way he approached and analyzed his welding.....identified the problem quickly......and started running nice beads.....this is actually a very good video for beginners.....well done...

[@linusfzj80]

I been welding for years & we all forget the ground (esp when excited to finish) - cool to see a guy doing a new process for 1st time - My Dad has the 211, and he loves it - plenty of expansion/use! There is no such thing as too clean trying to do aluminum - it'll pay off trying to get the stacked dimes & an effective bond.

[@worktravelplay3071]

Good video, enjoyed your honesty and enthusiasm. For the first timer at ali welding I am looking forward to giving it a go now.

[@destinywalker1959]

I'm glad I went with tig! The spool gun looks quite tricky and at 3/4 inch and a fan your not getting much gas!

[@joewest1972]

Good job on the video it is intimidating to do this kind of thing live for the first time. if there's definitely a specific application for welding aluminum with MIG welder but it's not short runs on small pieces however this is only practicing this is how everyone learns

[@brianpooley6635]

Love this, I guess I'm not the only one that would show this without trying it first. Learn more from the mistakes than a lucky hit. Keep up the interesting tests.

[@gheumann]

Thanks for this. I'm just learning, still MIG on steel- but I plan to get a spool gun and learn alu too. This helped me see what I'm up against - and advises me I probably ought to buy a pack of spare tips when I start!

[@themainproblem]

We started using our spool gun at work using the exact same method that you are using. We found that the aluminum plate liked it hot and fast aluminum wire delivery for decent results. I imagine that if one practiced or used the spool gun everyday some amazing results could be had. Keep up the great efforts Brian and greetings from Arizona.

[@outdooreng4973]

I just started mig welding with spool gun a few days ago ,, I am really need some encouraging because I am not even make one seem line , all my welds look like dots and not clean, every time the tip stuck with feeding wires and I had no idea why that’s happening Please I need to contact with you to get some basic

[@briansmobile1]

Thanks for the encouragement! I weld side to side too. And you're right- the camera has it's own effect- kind of rushes you/distracts you.

[@Velvethamma]

Good impromptu video. I've never welded aluminum but I'm watching to get the basics. Thanks for taking the time to make the vid

[@apollomegablue]

Thanks for the tape. I think the comment about keeping it clean is very important. Look forward to your next spot Steve

[@tracybrislin]

Thanks for honesty and persistance, Fun to see your approach to mistakes, being human that's gonna come with trial and error.

[@briansmobile1]

Practice and surface preparation I'm learning is also very important. Aluminum is VERY picky when it comes to cleanliness.

[@briansmobile1]

It just makes you feel cool. ; D It's kind of like dressing up as Batman or Superman when you're a kid. Welders are like toys for grown ups. I worked my arse off as a kid- now I'm all grown up on my own I can play.

[@briansmobile1]

3/4" is a good stick out. I wouldn't say I've done well going fast. Doing short sections and allowing the work to cool between has worked best.

[@topallielton]

Thanks I just got one yesterday. I was doing the same thing last night lol. Thanks for the time and sharing.

[@SuperKwame1]

Thanks for the video, It takes a man like you to do it on a camera at the first time. I'm still learning.

[@mbrenengen]

Love this video. For us novices, this is what we need to build confidence. Haters gotta hate. F-them.

[@ltcduggins]

Guy - I really appreciated the video, and especially that I'm not the only one who says things like "full-meal deal", "motate" or "be kind-rewind" in everyday life. Thanks again!

[@themainproblem]

You did a great job! This is exactly how I learn and advance myself. The first steps can be very nasty and discouraging but don't you give up! If you go through 100 tips then so be it, you will master the machine... I learned to TIG weld from KZbin videos and my first efforts were very ugly. And now my stainless steel and tungsten weld are very nice. Thank you for your video and don't ever give up.

[@briansmobile1]

You're welcome- thanks for stopping by.

[@briansmobile1]

I was welding on some badly weathered and poorly cleaned scrap aluminum. Since buying brand new clean material that is even super thin, it's easy. The contaminants are what make it so hard. I also recommend using a laser temp gun. If it accumulates too much heat from welding too long on it, the whole piece goes to mush. Patience and cleanliness are key to successful welds.

[@anthonymazziotti1605]

I JUST BOUGHT A SPOOL GUN AND YOU MADE ME FEEL LIKE I DID THE RIGHT THING.YOUR FUN TO WATCH.

[@briansmobile1]

Thanks for the feedback!

[@briansmobile1]

My preference is of little consequence- life teaches a person much more when they are open to having the experience. I enjoy learning in whatever language or discipline I can.

[@4randysgirls]

So I always wanted to learn how to weld aluminum. So I searched for "how to" videos and ran across yours. It was a deciding factor of what welder to buy. So I bought the same exact one and it's out in the shop waiting for me to make the same mistakes...can't wait to burn out all my tips...FYI. I bought extras....thanks Brian. Enjoyed the humor in the videos.

[@14DFASniper]

Perfect video. I'm not a welder either but this is how to learn. Get as much information as you can and then learn by doing the task. Correcting mistakes and keep trying.

[@GuestInvitado-gd3bi]

Nice spool gun you got there. I've never used one, but I am looking forward to try. Since, I already have the welder (HOBART 210), I want to go for it. Thank you for sharing and take care my friend.👍👍

[@XagentTM]

I am not a welder. My brother is though. I watched this video as he needs to weld some aluminum for me. I enjoyed watching your video. It was also refreshing to see how honest you are with your own learning and results.

[@getphuked2]

great vid man, I hv never done it before but fersure want to buy one forever

[@brucecaldwell6303]

I have the same machine & spool gun. The first aluminum job I did was on 4" square tubing with an 1/8th wall. It worked great except for the inherent cold starts.

[@munoztorresjose79]

Notice how much fun he's having though. You're going to be awesome at this if you're not already !.

[@austinsaunders2616]

My first time ever welding aluminum was actually a weld test for a job opportunity for after i graduate high school. thank god u i had alot of experience in mig that i applied to it lol. great video man!

[@blankreg9745]

I have just ordered my spool on gun, so in a week I will be doing the same. your vid has help me, thanks :0)

[@briansmobile1]

Both. It just depends how thick the material is. I don't use the 220 unless it's needed. I have fewer of those outlets around the shop.

[@mxmike123]

Thanks man, you just made me feel better about my first spool gun weld!

[@user-xn4fm2dh1n]

Just love the style of your studying and working.

[@briansmobile1]

I started off with Arc. It's pretty cool for thick materials.

[@dansmovingtrucking1314]

Brian : I mig- welded aluminum with a spool-gun for the 1st time back in 1989 I purchased a Lincoln SP-150 and the dealer hard wired and plumb the connection for the spool gun. And when I was looking at your plate, I reminded me of my plate. I had a plate of the same dimensions ! However I went about it differently than you. I filled one side of the with 3 to 6 in beads with 1 inch spacing between the beads; like double-space on a typewriter. The method that I was employing was to heat up the plate each pass and stagger the heat across the plate evenly similar to torque sequence on a v-8 intake manifold from the middle then eventually out to the corners. As the plate got hot ihad to get-up go to the machine and turn down the dials. I still have not mastered that spool gun and every time I had a welding job, not only did I warm up the metal; but I had to warm me up or acclimate to the unpredictable outcome of what the mig-aluminum process was about to yield. My most successful job was 2 broken handles a-top of professional appliance dolly. And it was the hottest day of the summer and I welded it at 3 pm after it had warmed up to at least 90 degrees all morning. The point of this story is yesterday I finally purchased a Miller Diversion 180 TIG machine with foot pedal I won't have run back to the machine anymore to adjust the Amps and wire speed. I am also looking forward to build some stainless exhaust headers. IJust finished reading: " Brought to you by Miller...TIG Welding For Dummies" by; John Swartz & Brad Hemmert ISBN: 978-0-470-24455-5 and I put the ISBN # out here because I kinda wished I'd read this book ahead of time before making the financial commitment. P.S. I liked your video, and keep up the good work.

[@briansmobile1]

Thanks for your book recommendation Dan: Aluminum isn't easy. It takes getting used to. I would compare it to skiing. The condition of the snow and the type of ski you use greatly impacts technique and what kind of day you'll have. And the very next day conditions are different. Ultimately it takes practice, experimentation, and some helpful advise from someone with more hours than you have. Thanks also for the encouragement!

[@michaeljupp]

saved me some painful trial and error, i bought one about 3 months ago but didn't get argon til now, looks like i better go get some spare tips. Good vid, thanks

[@jeremyc9229]

You see and understand things, I bet you are really good at this now!

[@marititi64]

I like you sharing that experience now I know that to do and what no to do thanks

[@briansmobile1]

Right on- best of luck!

[@donipock394]

Hey Brian, Tks for the experience. We are ready to get our first mig welder. Leaning on the Millermatic 180 and the extra spool gun for aluminum. Don't feel alone, I lost a bottle also. Kept the burn on. Don

[@THEMOWERMEDIC1]

i love my wire welder (lincoln 100)......its flux core so i can weld outside....its spool gun adaptable so i may go this route....great vid brian

[@carlmcgaughey7745]

appreciate the fact that you show the leaning process. Thanks.

[@4tusix]

i bought the same welder,,,,,before they had been shipped out of the factory,,,had to wait a week to get it,,,,great welder,,,,next year i bought a miller plasma cutter,,,,,if you don't have one you must get one,,,,,will speed up almost any project,,,,oh and heat what your welding on when using aluminum,,,,helps alot

[@briansmobile1]

4tusix I have a CUT50 plasma cutter. I actually had a chance to get a demo Miller for $400 off, but was hesitant and it was gone the next day.

[@twalters4812]

Thanks for sharing this video. Truely helpful for me by seeing this real life experience.

[@karroome]

You got my thumbs up when you forgot to hook the ground up.....you're awesome.......

[@shouldbeasy9721]

I did the exact same thing... too excited!!

[@briansmobile1]

Good. Glad to help!

[@ThePhx1911]

Props to you for having the balls to first time it on video. & Jody's the man I've learned so much from his videos Great to have people take the time to share Pro or first time thanks.

[@briansmobile1]

THANK YOU!

[@briansmobile1]

That's correct. When using this process you have to think "push the spray" not "drag the bead." I would love to do a follow up. Thanks for showing interest. I just bought some material today!

[@SuperKwame1]

Hi Brian, Thanks for this video my brother. I just ordered MIG 211 from Miller. I just can wait to try it.

[@briansmobile1]

Thanks Victor!

[@bxs204]

Sweet...thanks for the lesson Brian...your the man..peace off!

[@chipkinnett]

Thanks for the video, I just got a Millermatic 180 with same spool gun. I found your video after laying some hideous "welds", and was amused to see you have the same issues as me with the hose clamp, feeding the wire, forgetting the ground clamp, and burning up a tip resulting in a huge mess in the gun. Glad it's not just me!

[@Ghostwriter69]

I really liked to see how the setup and first attempts go. Very interesting. I have a Miller 210 and was wanting to try aluminum too. Keep up the good work.

[@briansmobile1]

Thanks Skip!

[@superkwame1904]

Hi Brian, Thanks for this, I just purchased a Miler 211. I'll be doing the same thing, so this comes handy.

[@briansmobile1]

I was at US Welding today talking to Todd about buying a TIG setup. For something decent it's about $2k plus tank, rod, and electrodes. This set up is about $200 plus tank and wire.

[@briansmobile1]

Thanks Raphael!

[@TimsLawnTaming]

i think you did a realy good job for your first alloy weld.. i wish i could weld half that good on steel!

[@briansmobile1]

Also a big reason for the black in this example is material impurities (dirty aluminum that has been outdoors in the dirt for years) and air movement in the shop blowing the gas away.

[@briansmobile1]

Right on- I've got a CUT-50DX. Hypertherm 45 would be SWEET!

[@panamamfred]

dude!!!! you make my life!!! thank you.

[@dogbyte555]

I just picked up a digital thickness gauge at Menards for $10.00. It looks pretty cool.

[@repairfreak]

Thanks for your bravery to actually video your 1st attempts. I believe your tension is set by how tight you screw down the nut on the spool gun. I would be welding left to right or right to left while pushing with the recommended angle, that way you aren’t burning your glove up. Also when changing wire from internal spool in machine or disabling, just cut the wire at the contact tip of gun, pop the tension off the drive rollers and turn the spool to wind your wire out of your gun and whip back onto the spool. This way you don’t waste any wire left in the whip. All GSMA welders require a polarity change from steel to aluminum. I believe the switch on the front of your machine “gun/spool gun” does this. On other machines you actually must change wires over under the lid. Always make sure your gas flow rate is correct and that you don’t have a draft. I’m sure with practice you’ll get the hang of it. Vital to have the aluminum very clean and grease free as well. The machines instructions and setup charts are all very important to read when anyone starts a new process. Best of luck my friend.

[@Trex1268]

I have the exact same setup. Jody's a professional that makes it look easy. Aluminum is tough to get down. As it heats up travel speed also has to pick up or you just melt it. I've actually learned more from watching you than Jody. The black soot issure I've never got rid of. It's supposed to disappear with a push, but mine never has. I'm gonna try again in the spring. Good luck!!

[@will6825]

We're learning with you. Good job!

[@briansmobile1]

Well spoken sir.