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How to set up and use a MIG welder

set up and use a MIG welder

Overview

MIG (Metal Inert Gas) welding is a popular among D.I.Y. enthusiasts for its versatility and ease of use. This welding process involves using a wire-fed welding gun to join two metal pieces together. It’s suitable for a wide range of applications, including automotive repairs and customisations, building and fixing metal gates or fences, creating metal sculptures or repairing metal tools and equipment.

Before diving in, it's important to follow proper safety procedures and prepare your workspace accordingly. Whether you're MIG welding aluminium or MIG welding stainless steel, we'll walk you through the steps to set up your MIG welder and provide advice for achieving optimal welding results.

Safety tip: Always wear the appropriate safety equipment (safety glasses, gloves, ear muffs and a mask, for example) and always follow the instructions for the product or equipment.

Steps

1Take proper safety precautions

Safety should be your top priority when working with any welder. Welding generates high temperatures that can cause sparks and hot metal pieces to fly off the welding area. To reduce these risks, work on a non-combustible surface such as steel, concrete, or a welding table.

Before starting MIG welding on aluminium or steel, clean the surface you'll be welding on to remove rust, paint, and other contaminants that could interfere with the weld. Make sure you have all the necessary safety equipment, including a welding helmet with a filter lens, welding gloves, protective clothing, and a curtain.

Mig welding requires safety and preparation

2Attach the spool hub

First, attach the spool hub. To do this, open the side door of the machine, remove the spool hub nut, and place the spool of wire on the spool hub. Replace the nut.
Attach the spool hub to your mig welder

3Release the wire feed

Next, release the wire feed tension by pulling down on the wire feed tensioning knob. Remove the drive roller cover and make sure that the drive roller matches the wire size needed for the job. Check that the correct wire size on the roller is facing out of the machine when fitting it.
Mig welding and releasing the wire feed

4Remove the drive roller cover

Once you've checked everything, replace the drive roller cover and plug the machine into a 10amp socket.
How to remove the drive roller cover from a mig welder

5Feed the wire

Now it's time to feed the wire. First, grab the end of the wire and guide it into the guide tube over the drive roller groove. Make sure to hold the wire spool securely and keep an eye on the tension to prevent the wire from unravelling. Keep feeding the wire until it passes into the inlet tube, which should be about 100mm. Once the wire is in, use a wire cutter to snip it off to prevent the spool from unravelling.
Mig welding and feeding the wire

6Lock and tighten the tension

Next, lower the wire tensioning arm and ensure it locks into position. Gently turn the wire feed tensioning knob to tighten the wire tension.
Lock and tighten the tension when you’re mig welding

7Prepare the torch

Prepare the torch by removing the nozzle and tip. Turn the machine on using the power switch at the back of the machine.
How to prepare the torch when mig welding

8Release the wire

To release the wire, simply press the trigger button to activate the wire feed and allow it to pass through the torch. Release the trigger once the wire appears at the end of the torch. Once the wire has fed through, reattach the tip and use welding pliers to trim it.
Green Bunnings hammer
Tip: Ensure your torch is laid out straight during this process, as it's important for a successful weld.
Mig welding and releasing the wire

9Attach the ground clamp

Attach the ground clamp. This is an important step because it completes the electrical circuit between the welding machine and the workpiece, allowing the welder to function properly.
Attach the earth clamp to your mig welder

10Set the welding voltage

Refer to the settings chart on the front of the machine, as well as the machine's instruction manual, for guidance on suggested machine settings and material thickness. This will help you achieve the best welding performance.
Set the mig welding voltage

11Try arc welding

We’ll show you how to set up and use an arc welder.
Health & Safety

Asbestos, lead-based paints and copper chromium arsenic (CCA) treated timber are health hazards you need to look out for when renovating older homes. These substances can easily be disturbed when renovating and exposure to them can cause a range of life-threatening diseases and conditions including cancer. For information on the dangers of asbestos, lead-based paint and CCA treated timber and tips for dealing with these materials contact your local council's Environmental Health Officer or visit our Health & Safety page.

When following our advice in our D.I.Y. videos, make sure you use all equipment, including PPE, safely by following the manufacturer’s instructions. Check that the equipment is suitable for the task and that PPE fits properly. If you are unsure, hire an expert to do the job or talk to a Bunnings Team Member.