Presently I have a Lincoln Weld-Pak 100 set up with .035 flux core wire. I am thinking about changing to the .030 flux core wire for a bodywork project. The instructions on the welder deal with only the .035 wire settings ("B" volts and 1.5 wire speed). How much will I have to change the settings to accomodate the smaller wire? Can I just boost the wire speed and leave the voltage alone?

Presently I have a Lincoln Weld-Pak 100 set up with .035 flux core wire. I am thinking about changing to the .030 flux core wire for a bodywork project. The instructions on the welder deal with only the .035 wire settings ("B" volts and 1.5 wire speed). How much will I have to change the settings to accomodate the smaller wire? Can I just boost the wire speed and leave the voltage alone?

Well with .035 flux core I hope your are welding on your frame. Don't even attempt to body panels with that. You need .025 wire with gas to do body panels. I don't care how good a welder you are you will never be able to use flux core doing body panels....trust me!

go down to your local welding supply company and purchase the gas conversion kit for about 100 bucks.it comes with .25 wire,tips,new liner and a regulator with hose.then you can rent a bottle of argon/co2.it will be the best money you spent on that thing.

I just did the Mig conversion on my weldpac 155 a few months ago. I was using .30 fluxcored wire previously to the conversion, and I can tell you from experience that it'll blow through sheetmetal, and or warp the crap out of it.

Another thing I can tell you is that the machine is totally different. I figured that it'd just be a minor voltage change, maybe change the wire speed a little. But it's a completely different animal... I had to Re-Learn how to weld with it.

Apparently, no one here has tried this stuff. I have found some very positive remarks about the .030 flux core wire called "Twenty Gauge" (Shotgun on label) from J. W. Harris (now owned by Lincoln , I think) on some of the hotrod sites. So I will give it a try and let you know how it works.

he must mean this heres the link

http://www.harrisproductsgroup.com/consumables/alloys.asp?id=12

any tried this stuff?

My 110 volt welder was crap till I put .020 wire in it.

I think a lot of the problem is with the operators. I used .030 flux core wire for years in my cheap 110 Montgomery Ward welder welding everything on a car that can be welded. I never had any problems. The only reason I replaced my welder was to buy a bigger one that would weld very heavy steel.

I think a lot of the problem is with the operators. I used .030 flux core wire for years in my cheap 110 Montgomery Ward welder welding everything on a car that can be welded. I never had any problems. The only reason I replaced my welder was to buy a bigger one that would weld very heavy steel.


It's not that I am saying that it can't be done.... because with enough time and patience anything can be done. With my Lincoln 155 I couldn't turn the current down enough (220V) to keep it from blowing holes in most sheetmetal. Especially butt welding. Now plug welding, I have done that with .030 wire, and I had to be very carefull not to blow through. I still keep the 11lb spool around for when I do any thicker metal. The Mig conversion with the .025 is a breeze welding sheetmetal, doesn't warp it (it will if I try) and the welds are nice and clean. No Slag, the amount of dingleberries is substantially less.

Slight Highjack here....

Can .025 w/ gas be used on heavier materials as well? I have my machine loaded up with .025 right now, but am planning to box some lower control arms. Would like to avoid changing wire if it isn't necessary.

Slight Highjack here....

Can .025 w/ gas be used on heavier materials as well? I have my machine loaded up with .025 right now, but am planning to box some lower control arms. Would like to avoid changing wire if it isn't necessary.


Boy that's a loaded question and a half... It really depends on the welder. I'm pretty sure that My welder would have no problems doing something up to about 3/16" (It's a 220V) using the .025 wire. but I'd run a couple of test beads on some scrap to test the penetration.

I was having a heck of time learning to weld and today I went and bought me a bottle of welding gas and what a difference it made. I don't know how to weld very good but getting the gas sure made the welds look a 100% better:thumbsup:

You might try a self tinting welding hood. Mine made a big improvment in my welding....now it's only bad.........it was worse!