I recently swapped out my old flux core wire roll, and since there was still about 2 feet left in the MIG gun, I thought I’d share a simple guide for anyone doing the same. It can seem tricky the first time, but it’s actually pretty straightforward.
What You’ll Need:
- Your new roll of flux core wire
- Wire cutters
- Welding pliers (optional but helpful)
- Safety gloves (recommended)
Step-by-step:
1. Turn off your machine
Unplug or switch off the welder for safety.
2. Open the wire feeder area
This is where you access the wire spool and feeding mechanism.
3. Cut the old wire
Cut it close to the spool but leave about 2 feet of wire still running through the MIG gun. You can try splicing it, but if it doesn’t feed smoothly, just pull it all the way out.
4. Remove the old spool
Take out the empty or almost-empty roll.
5. Load the new spool
Put the new wire spool on the spindle, making sure it feeds from the bottom of the roll (clockwise) toward the feeder.
6. Unwind 6–12 inches of wire
Straighten the wire a bit with your fingers to help it feed smoothly.
7. Align the new wire at the cut
You can try feeding the new wire right in, but if it jams or doesn’t feed well:
8. Remove the leftover old wire
Pull out the last 2 feet from the MIG gun completely, then insert the new wire from the start.
9. Feed the new wire through
Guide it through the rollers and into the liner. Close the roller tensioner if it’s open.
10. Turn the welder back on
Hold the trigger on the MIG gun until the new wire feeds all the way out the tip.
11. Trim the tip
Cut the wire to about 1/4 inch (6mm) sticking out of the nozzle.
Pro Tip:
Some welders twist the old and new wires together to feed them as one, but this often causes jams. It’s usually better to just remove the old wire completely and start fresh.
