AL TIG Practice

[Arizona Joe]

If you really want that welding job in the CNC shop I suggest you throw a few test coupons of your TIG, or other, work in your car. Then seek out the person who has the final say in hiring decisions such as the welding shop supervisor or manager. Don't bother with Human Resources or other administrative...

[Arizona Joe]

That's exactly what the spec says.
...

[Arizona Joe]

As expensive as it is, $2000 to get your machine repaired is cheaper than buying a new one, and it would not be chasing good money after bad by buying an Everlast. The only thing I would suggest is that you insist that the service tech returns the bad boards to you. Then someone would have a chance...

[Arizona Joe]

Especially since you can get a red one for $1449.

http://www.lincolnelectric.com/en-us...incolnElectric)

http://www.lincolnelectric.com/en-us
/Equipment/Pages/product.aspx?product=K5126-1(LincolnElectric)...

[Arizona Joe]

Is RC 30 an output from PC1 and in input to PC7? If so, I would try disconnecting RC30 and measuring the voltage off PC1. PC 7 could be loading down the voltage to 160 V. If RC30 reads 160V with PC7 disconnected, then it probably is PC1, or if it reads 460V then it is PC7....

[Arizona Joe]

IMO it is unlikely that multiple boards are out. I would trace input power wires to the power supply (PS) they go to. Then with the machine on see if the PS voltages look OK. The hardest working modules, like the PS, are most likely to fail. Ask Miller what to look for. In your pix, those two big...

[Arizona Joe]

+1 again

While I can understand resistance to going open source hardware, I cannot understand why Miller does not provide schematics and service manuals. Inexcusable in my view. The OP is the owner of an old school machine and can't get service information. Can anyone make a good defense...

[Arizona Joe]

+1

I would go a step further and suggest that Miller provide the service manual, schematics, gerber files, and BOM, to anyone. In other words, make the boards "open source hardware." Miller customers already pay a premium for the machine. They ought not get ripped off for service....

[Arizona Joe]

My neighbor's cowboy nephew made her a saguaro cactus sculpture of horseshoes using MIG. Well, we had some windy weather that bent it over. I volunteered to repair it for free. Dug it up and dragged to my garage and then welded it with my Maxstar 161 stick welder. First time I ever welded horseshoes....

[Arizona Joe]

You had a functioning welder before your mods, but after the mods the controller board failed? That seems unlikely to me. Was your repairman an official bona fide Miller service tech? Also, 900 bucks seems rather steep. Did you get that price directly from Miller?

I just think you should...

[Arizona Joe]

For the alloy content did you contact ford.com? There is a contact number where they say they will answer questions. Also, there are probably numerous clubs who have knowledgeable members to answer your question.

Lastly, I just chanced upon the video below about welding aluminum, especially...

[Arizona Joe]

Nice work on the modification!

I have a TA-186 and recently spent some time messing around with the pedal from which I got a knowledge of how the thing works.

I just looked at the schematic for the Div 180. It appears to me that it may work in a similar manner as my TA-186's....

[Arizona Joe]

If you Edit your post and then click on the pictures, a list will come up. For each picture you can select the size: Thumbnail, Small, etc. It is worth a try.

If that doesn't work, you can upload the pictures as Attachments, and then get the same size choices.

Cheers

[Arizona Joe]

I did Weyenberg's exercises of sliding your hand smoothly with the torch off and then running the torch without filler metal to make a uniform trail on the AL That last one was very telling, but now my bead is noticeably straighter. Thanks!

[Arizona Joe]

Scott Duggins' rhythm struck a chord in me that improved my AL TIG welding. This butt weld on 0.165" AL is the last one I did today after getting my machine dialed in. With it I finally feel that I have a handle on AL TIG welding. It took a long time to get to this point, and it did not come easy...