Retrofitting a MillerMatic 35 Mig Gun

[garybdavis]

I have a 1970s vintage MillerMatic 35 Mig welder. It’s been my main shop welder for over 10 years now. I think you could throw this thing off a cliff and it would still work.

When I purchased it used, it had been retrofitted with a Benard gun. Well, after years of dragging the lead around the shop floor, it just needs to be replaced.

It’s obvious that someone jerryrigged the lead to fit the MillerMatic 35 and I believe some of the original parts that would connect a factory replacement gun are missing. So, I went to Miller’s web site and downloaded the manual. However, the parts for the gun refer to another manual which I can’t find on their web site (I downloaded almost all the gun manuals). The manual it refers to for the gun is OM-1025.

It’s harder for me to find consumables for Benard. I now have to order them ahead or get them from a web store. I’d rather support my LWS. So, I’d like to switch to a more common gun. I’m guessing Tweco would be a good bet. I’d like to be able to purchase a generic brand gun if need be.

Any ideas on what to switch to and where to go for help? My first approach is to call Miller’s customer service Monday morning and see what they say.

[aametalmaster]

You can put on a new Miller M-15 or M-25 gun with no problems....Bob

[fun4now]

the miller parts book calls for a M-15 gun as the replacment gun. your LWS should be able to order you up on or you could probly find one on e-bay used where they changed it out for another gun of choice.

[garybdavis]

I downloaded the MillerMatic 35 manual and the drive section didn't resemble mine at all. So, I went back to Miller's web page and entered the serial number along with the model number and got a different manual with parts diagrams that match my machine. I still don't know what model gun this is, but the manual has a part number for it. I'll check with Miller's customer service tomorrow to see if it's still a modern design.

[garybdavis]

Well, Miller doesn't make the gun for my welder anymore. Too bad as the rest of the welder still runs strong. My faith in Miller's support has been somewhat dented. They did give me the phone number to Bernard. I need to email Bernard photos of the gun and the manual to see if they still make one that is compatible.

I guess that's the curse of making a machine that lasts a long time. Still, I tend to judge a company by how long they make parts available for their products.

[fun4now]

my miller parts book said it would take the M-15 as the replacement gun, i wonder why miller said no go on a replacement???

[fun4now]

the binzel ALPHA 2 is a good option its a 250 amp gun
http://www.binzel-abicor.com/showpag...mnu=241&lng=27
or the ALPHA 1 witch is a 180 amp
http://www.binzel-abicor.com/showpag...n&skd=0&lng=27
i would think the ALPHA 2 is a better fit and is less expensive option with readily available consumables.
you might look into one of theses options as a replacement.
we are having a similer discution about a replacement gun for a DVI on another board but the gun needs are simmiler.
hope this helps

[gweld]

Gary,

My first mig welder was a 1970’s Millermatic35s purchased used over 25 years ago. The machine came with a Tweco # 2 gun on a special Tweco adapter. I changed to a #1 Tweco gun using the same adapter. I would think that your lws has this adapter cataloged. I am away from the shop for a week or two if you need a pic I will be glad to snap one for you.

Ps I have visited this site many times, and never considered to join and post>>however I saw your trailer and to say I was impressed would be an understatement. You do superb work.

[imported_hotrodwillys]

Hi I have and still use everyday a Miller MM35 , I put a Tweco mini mig gun on it I am not sure of the part# but I know they still make them. I use the gun on everything from sheetmetal to dump trucks, and wire size from 23 to 35. I am sure if you call any welding supply they will hook you up.

[fun4now]

gweld
welcome good to have ya aboard.

[garybdavis]

Hey guys, look at the attached pictures and tell me if my MM35 is the same as yours. I know they made a later model that had a different drive assembly that the gun plugged directly into instead of attaching to the case like mine does. Mine is apparently the older style. It may not be pretty, but it lays down some pretty welds!

[garybdavis]

the binzel ALPHA 2 is a good option its a 250 amp gun
http://www.binzel-abicor.com/showpag...mnu=241&lng=27
or the ALPHA 1 witch is a 180 amp
http://www.binzel-abicor.com/showpag...n&skd=0&lng=27
i would think the ALPHA 2 is a better fit and is less expensive option with readily available consumables.
you might look into one of theses options as a replacement.
we are having a similer discution about a replacement gun for a DVI on another board but the gun needs are simmiler.
hope this helps

Hey fun4now, I called to Binzel a while back and the guy I talked with said he could rig up one for my welder. He said there wasn't one he couldn't make work. It was going to be expensive as I would have had to purchase the stuff directly from them. I hear good things about Binzel. Do you know how easy it is to get consumables?

[fun4now]

i dont personaly but from what i read in the other post they are verry easy to get. i would give your LWS a call and ask if they stock them. they are prety common guns and one of the bigger names so my guess is they would be pretty common and easy to find.
i can ask the guys on the other thread for ya but here is what they had to say. here are 3 post about it. sounds like a good option and i will be going with one when i replace my M-10 most likely.

The two I use the most are a 180 amp Binzel with the flex neck and Binzel Alpha-2.
Easy maintenance, standard tips, good ergonomics, knock-on-wood "no problems".

Ive got 3 Binzels and have never had a problem with any of them.Easy to get tips ,easy to change liners and the nozzle on the later models have a good gas seal.They are also light .I have Binzels connected to suit Lincoln and SAF .If I needed another gun I would get another Binzel as I have never had a problem with any that Ive owned but the only other gun Ive had was a SAF and found it cumbersome.Having said that, other brand guns may be just as good?

Look for a Binzel Alfa 2 for about $125.00 or less. It's a deal and also uses Tweco tips.

[fun4now]

last minuit post about its head being swopable with the larger one if needed

A Binzel alpha 2 would be a good size for all your short-arc work.
If you did a lot of spray-arc you could buy a extra swanneck
for a alpha 3. I really never needed the 3 swanneck but if does
use way bigger consumables. You just run a jump liner in the
swanneck. The gun body is the same size between models 1-2-3
You use to be able to run any swanneck on any model but they
changed the #1 so it no longer can interchange with the #2 and #3
guns.

here is a pic he posted with it, hope this helps.

[bigdogjoe62]

That looks like it had one of the old style miller guns on it with plastic connector and tips held in with collets and a nut they use to make an adapter to retro newer guns on them,but I think they stopped making them about 15yrs ago,when I started selling welding supplies about 20yrs ago I use to see a few of those come in the shop but even then they were fazing out the parts for them