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Hot Rods Mig Wire .023, .025, or .035?

Discussion in 'The Hokey Ass Message Board' started by Fortunateson, Oct 13, 2019.

  1. .023

    91 vote(s)
  2. .025

    15 vote(s)
  3. .035

    24 vote(s)
  1. LWEL9226
    Joined: Jul 7, 2012
    Posts: 319

    from So. Oregon

    Same here....

    doug j likes this.
  2. Sporty45
    Joined: Jun 1, 2015
    Posts: 1,021

    from NH Boonies

    .030 here.
    osage orange likes this.
  3. .023 for sheet metal here also... .035 for heavy stuff.

    But have used .035 flux core before for sheet metal.
  4. dodgedifferent2
    Joined: Mar 8, 2006
    Posts: 117


    .023 wire is hard to obtain around here. It's like a needle in a haystack.

    I usually run .025 wire for everything. Yes I have welded some 1/4 plate with the .025 wire.

    I do have a spool of .03 wire but for most jobs that I would switch to .03 I walk over to the arc welder because it's easier to setup.

    When i bought the lincoln 220v welder it came with a roll of .035 coreflux wire. Which I tried once and did not like the way it welded. Back to the arc welder.

    The mig is mainly used for anything thinner than 1/8 inch.
    Anything above go for a real welder with some 7018 rod.

    I have never tried tig but as my father (40 years of welding) found out. His brain, eyes, feet and both hands dont work together to tig weld. I want to bust out the tig welder at work sometime and play to see if my limbs can work together
  5. southcross2631
    Joined: Jan 20, 2013
    Posts: 4,414


    I use .023 in my Hobart for sheet metal and .030 for chassis and roll cage welding. Anything heavier I use my stick welder. Don't have a tig welder. May buy one this year.
    I still gas weld my headers . Goes back to my days at Midas muffler in the 60's I guess.
    doug j and dirty old man like this.
  6. mrharley51
    Joined: Sep 16, 2007
    Posts: 225


    yes, change nozzle with wire change...have not changed liner...same one for both
    flatford39 likes this.
  7. alanp561
    Joined: Oct 1, 2017
    Posts: 2,003


    If you have a DC stick welder, why buy a tig welder? All you need is a tig torch, regulator and hose. Reverse the polarity on your stick machine and go to work.:)
    Montana1, j-jock and Algoma56 like this.
  8. alanp561
    Joined: Oct 1, 2017
    Posts: 2,003


    Mig wire size depends on the application.
  9. DDDenny
    Joined: Feb 6, 2015
    Posts: 15,625

    from oregon

    I actually did change EVERYTHING, the only thing I didn't do was throw that "firehose" of a Miller gun assembly in the trash and buy a Tweco.
    Dick Stevens and alanp561 like this.
  10. finn
    Joined: Jan 25, 2006
    Posts: 932


    Same here. My HTP 120v is ready to go with .023, and the 240v Miller is set up with .035 (and CO2 came that way).

    I use the 120 v HTP 90% of the time.
  11. papadaddio
    Joined: Nov 13, 2005
    Posts: 31

    from Minnesota

    .030 for everything..
    osage orange likes this.
  12. Ebbsspeed
    Joined: Nov 11, 2005
    Posts: 5,671


    Yes, here's a good short video with some tips for using a DC power source from a good ol' Kansas welder! has a lot of video's available for all kinds of welding situations.

    Montana1, alanp561 and belair like this.
  13. Budget36
    Joined: Nov 29, 2014
    Posts: 7,569


    Did you change the liner, rollers and tip when using the .023?
  14. Degenerate
    Joined: Aug 5, 2007
    Posts: 239

    from Indiana

    030 works for everything I use my mig for. HTP 160 that I bought in 1993. I also have tig, and ox-acet. Can use my tig power supply to stick weld if I needed to.
    osage orange likes this.
  15. DDDenny
    Joined: Feb 6, 2015
    Posts: 15,625

    from oregon

    See my entry five posts back.
  16. belair
    Joined: Jul 10, 2006
    Posts: 8,806


    Cool video, @Ebbspeed . Gives me hope for my old Sears stick welder.
  17. Stooge
    Joined: Sep 9, 2015
    Posts: 502


    .030 for everything I do, lots of sheet metal and some heavier chassis stuff. I hate having to swap wire around, and its what I am used to using for years
  18. Nostrebor
    Joined: Jun 25, 2014
    Posts: 1,208


    .030 for almost everything I do.
  19. mickeyc
    Joined: Jul 8, 2008
    Posts: 1,297


    My Miller 252 unit will only go as low as 14 volts. I find that 030 wire actually helps on 18 or 20 gauge to act as a heat sink and allows for better control with less blow through. I do use 023 as well. Mostly 030. I can and do dial it up and 030 works for well for structural components.
  20. goldmountain
    Joined: Jun 12, 2016
    Posts: 3,183


    Went to the garage for a look. .035 from Princess Auto. Never really gave it much thought.

    Sent from my SM-T350 using The H.A.M.B. mobile app
  21. gene-koning
    Joined: Oct 28, 2016
    Posts: 2,640


    .035 for everything, 20 gauge sheet metal can be a little challenging, but I have gotten pretty used to it now.
    Now that I have retired, I might switch over to .030, but I'd have to buy new rollers & tips. Gene
  22. mopacltd
    Joined: Nov 11, 2008
    Posts: 935


  23. 8flat
    Joined: Apr 2, 2006
    Posts: 1,382


    .030 but after reading all these comments it has me wondering if I should be looking at .025 for sheet metal....
  24. evintho
    Joined: May 28, 2007
    Posts: 1,910


    .023 in the Lincoln for Sheetmetal, .035 in the Hobart for heavy welding.

    INVISIBLEKID likes this.
  25. jaw22w
    Joined: Mar 2, 2013
    Posts: 1,407

    from Indiana

    My welder came set up with .035. I set it up for .023 for it's first sheet metal job. I have never changed it back. I find it good for every thing on a hot rod. I even built my log splitter with .023. Some pretty heavy welds. It obviously fills slower, but takes less amperage to run. I find it much more controllable. You can always put in a root, then multi -pass for heavy stuff.
    Montana1 likes this.
  26. Atwater Mike
    Joined: May 31, 2002
    Posts: 10,728

    Atwater Mike

    I had a problem with tig at first...same thing. Coordinating foot with both hands?
    Hell, it was like driving while oxy-acetylene welding!
    Finally got onto it with practice, but tig is slower than I can usually tolerate.
    (spoiled by mig speed, sometimes I oxy-acet weld things I want perfect, but some of my 'perfection' is lost from seldom welding. (oxy-acet)
    Welding is like...getting to Carnegie Hall: Practice, practice, practice.
    Montana1 likes this.
  27. Midnight 50
    Joined: Jul 27, 2008
    Posts: 568

    Midnight 50

    The old Miller 211 loves that 030 wire, which isn’t an option in the poll. It’ll do anything. Currently working on my Jeep CJ doing panel patches.

    Attached Files:

  28. Dirk35
    Joined: Mar 8, 2001
    Posts: 2,049


    I use .030 because that is the size of the tips I have.

    I get my wire from the Farm Supply store and I think they use the .035 more because they seem to have more products for it (tips, liners, and different brands of wire), but they usually have what I need in stock for the .030. For all I know, they might just have more of the .035 in stock because less people use it.
  29. trikejunkie
    Joined: Dec 2, 2011
    Posts: 103

    from Scotland

    I use 0.6mm for sheet metal with a tip for 0.6mm and 1.0mm with a tip for 1.0mm for heavier plate and angle - but I`m neither a sheet metal worker or welder.....I just get by and have done for 30 yrs with the same machine.I do have TIG as well for delicate work and stainless steel my 2c
  30. morac41
    Joined: Jul 23, 2011
    Posts: 530


    For the Aussies who don't do maths, 23 is .6mm 30 is.8mm 35 is .9mm approx..... .6 is what I use for sheet metal wouldn't use a mig on chassis work unless it was 415v feed....mainly use stick on anything over 3mm

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