Melted my torch!

Welding a frame for a Segway clone project fabricated of 'H' aluminum 1/4" thick and it got pretty darned hot. I noticed a black blotch of something on the frame where I had been welding and behold, I had melted a wedge out of the torch handle....Now I would have thought that it would be made from something a bit more 'tig torch' appropriate like a high temperature plastic maybe.

Anyhow; this 255EXT is one good welder. I was a bit apprehensive about it at first but cranked the amperage up to 200 to weld this 1/4" aluminum with frequency set at 175Hz and 30% EP. I'm amazed!! I used to weld years ago with a Lincoln 300/300 on aluminum but this 'little' Everlast being cutting edge technology does just as well if not better with all the features it has...

That's really why I posted - to give a big thumbs up to this new 255EXT welder and how well it does on aluminum. If it welds this well on aluminum, you could probably find settings on it to weld dog turds together! A melted spot on the torch handle is just a beauty mark - personality!

Thanks Everlast! You have proven yourselves to us for sure. :D

Bill C.

Everlast also sells CK torches that plug and play.

That is temp resistant plastic! If it was the 9 series that you were welding with, not much you can do about melting something when you are welding at 200 amps. It's meant for 125 amps or lower.

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Originally Posted by performance

That is temp resistant plastic! If it was the 9 series that you were welding with, not much you can do about melting something when you are welding at 200 amps. It's meant for 125 amps or lower.

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Yes, I know better than that! The torch is the 20 series - water cooled you know....? The melt wasn't due to the action of welding with the torch but allowing it to contact some hot aluminum. And NO it is not temp resistant plastic or it wouldn't have melted so quickly. Thanks anyhow Mark....You didn't read too much of my post.... Not so keen on compliments so maybe someone pissed in your cornflakes?

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Originally Posted by zoama

Everlast also sells CK torches that plug and play.

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I don't see a parts breakdown on the Everlast site for CK torches....

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Originally Posted by BillC

I don't see a parts breakdown on the Everlast site for CK torches....

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They're not on there yet. Call sales to get anything you need.

Hey,

It's nice to see the feedback on the 255EXT. I have the 210EXT, that I like well.

The title of your thread/post seemed to indicate that you melted your gas-cooled torch by exceeding its amperage rating, rather than merely letting the plastic handle touch on a 3000 degree piece of aluminum...

Why not post a forum thread title with clarity of your stated real intention, about how "The 255EXT ROCKS, and Here's How!"?

I think some firsthand user/buyer feedback would be very welcome to many, as there's not a lot of it around that I've noticed on the 255EXT, and it has very few competitors in its class, feature set, and price point, I think. I mean, I'd even also like to hear from a users of various EXT model users about how they best utilize their EXT with settings and certain features for certain projects, since I've only done a couple of small aluminum projects with mine so far.

A post like that may be worthy of some complimentary feedback, too.

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Originally Posted by BillC

Yes, I know better than that! The torch is the 20 series - water cooled you know....? The melt wasn't due to the action of welding with the torch but allowing it to contact some hot aluminum. And NO it is not temp resistant plastic or it wouldn't have melted so quickly. Thanks anyhow Mark....You didn't read too much of my post.... Not so keen on compliments so maybe someone pissed in your cornflakes?

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christian,

The title of the post said it was melted, nothing about exceeding the torch rating.... The first post explained the title. Should have realized that it sounded like a disaster - but not so much.... Got the wrong type of attention.

I don't see much on the forum about welding aluminum either....what there is gets off on argon cylinders, their size and price. The actual welding is never really addressed.

Setting up the 255EXT is a little tricky at first but experimenting with settings and checking the operation manual helped considerably. The first welder (255EXT) blew breakers right out of the box so this replacement one has been watched too closely sort-of like expecting problems.... After the experimenting and going ahead and cranking up the amperage it worked fine on the 1/4" aluminum 'H' extrusion. The HF works great and cleans the aluminum very well and setting the frequency as well as arc balance have a definite effect on penetration and puddle size. Working in a corner is where the higher frequency will help confine the arc into the tight spot. (I did need to go to 1/8" tungsten 2% L. to handle the higher amperage.) I'm still in the beginnings of the learning curve with this machine but so far it has been a pleasant surprise (over the first one!) and seems to be quite capable.

I'll be happy to return and relate as things are melted... working in a tight hot spot is detrimental to the torch, tungsten and gas nozzles. I changed to a long #5 nozzle with the 1/8" tungsten to reach into this structure. I had the frequency all the way to 200 Hz to see the effect. It seems good for this situation at 125Hz and not as buzzy but dropping to 60 Hz and below increases the penetration greatly. Balance was 30% and as stated the amperage was finally set at 200 - using the foot control. (I'm not used to that because I always used the Lincoln Amptrol thumb control - I'm working on a duplicate for this machine/torch. It can get in the way occasionally but it is generally easier (for me) to control than the foot - sitting down.)

Bill C.

Hey,

Thanks for that feedback, Bill.

If you like hand amptrol devices, I'm primarily using the new CK SteadyGrip, even though I did initially buy an aftermarket SSC pedal for my 210EXT. The Steady Grip really is steady, and the pistol grip gives a better propping ability, I think. And since the grip keeps you hand off the torch itself, your hand stays cool, for those of us with air-cooled torches. TigDepot seems to be the only place that has ported these for Everlast units.

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Originally Posted by BillC

christian, ...Balance was 30% and as stated the amperage was finally set at 200 - using the foot control. (I'm not used to that because I always used the Lincoln Amptrol thumb control - I'm working on a duplicate for this machine/torch. It can get in the way occasionally but it is generally easier (for me) to control than the foot - sitting down.)

Bill C.

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