When things go wrong using a Mig Welding machine, its not 100 things going wrong. It's always 1 or 2 things causing your Mig welding problems... and it's almost always only one thing at a time.
The absolute #1 mig welding problem is a bad ground. Let me tell you a secret: your Mig welding machine is a cold hearted SOB! It does not care if you have a bad ground. It just keeps pumping out welding wire anyway. If you have ever pulled the trigger on a mig gun and it went Pop! Pop! Pop! and sounded like a drive by shooting, you probably had a bad ground. But take heart! It's not all your fault and it's an easy fix.
Mig welding machine manufacturers are in hot competition these days and just seem to cut corners on their ground clamps by not making them out of the best materials. Have you seen them? I mean please! They are so wimpy. But you can easily remedy the problem without even buying a new and better ground clamp.
Just get yourself some old welding lead or ground cable and cut off about two feet of cable. Then Strip off the insulation and tape the ends with electrical tape. Fold it in half and put the ends in a vise. Stick a screwdriver in the loop and twist it pretty tight. (When you are done it will look kind of like a French twist pastry.) Now you have a cool tool that gives you a constant ground. Why?
· Because it's copper, the best conductor of electricity.
· Its braided wire and has more contact areas than a rigid ground clamp.
When you clamp this thing to what you are welding using your old ground clamp, you have literally hundreds of little contact points that will never lose the ground...not even for a second. This is critical when mig welding because as I already mentioned, your mig machine does not know or care if you lose the ground for a second. It just keeps feeding wire. That is the number one cause for poor starts. Try it! This makes a much better mig welding ground clamp than what comes on most machines.
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