welding wire spool size?

[Mark Whiddon]

Hey guys,
I have a question, I have been using my wire welder and have always used 2lb spools (flux-core). I am a long time stick man and am new to the wire stuff. I have never had a problem with the 2lb spools rusting, but I use them up relatively fast (6lbs in the last 4 mo. or so). Here is the question. I have never tried the 10 lb spools because I have heard of rust being a problem. What's the deal? I can get the 10 pounders at 1/5th the price (price per pound) of the 2 pounders, but I don't want to be half way through a spool and be having problems with the wire due to rust. What kind of problems can I be looking for and would it be better for me to stay with the 2lb or go with a 10 lb spool?

[Rocky D]

I've had the same spool in the machine for at least 5 years. I have an HH90, the original Handler, and have never had a problem with rusty wire, and I live with in 10 miles of the Pacific Ocean. Go for the 10 pounder, just don't leave the machine outside, tho. :)

I thought I might add that I have used nothing but E71T-11 .035" in it. What I've noticed with fluxcore, is that the deposition rate is quite a bit less than solid wire, so you have to go slower and let it build up, only then will you get a satisfactory looking weld bead.

[Mike W]

One other thing, I use bare wire with C02. I tried flux core but was not happy with it. Seems like the bead was ok for an inch and then was intermittent. With gas, the bead is consistent. Just my $.02.

[gkoenig]

I have a 10# spool in my hh175 for a year and a half now and it still looks good. just a few specs of rust on it but it still welds good.

[brianw]

you said that you can get 10# spools for 1/5 the price per pound, if this is the case then even if you did only use half the spool you would still be saving money. Actually at 1/5 of the cost the 2# and 10# spool would be the same price? Anyways, it sounds like you go through enough wire where the 10# would be the better way to go.

[Dan]

Mark
On my two larger machines ( MM 210 and CK Systematics 175 ) I run 33 lbs of solid wire, and on my HH 175 I run a 10lbs roll of solid wire. Since I have three different machines, one these rolls can end up lasting me a couple years. Ive never had to discard a roll because of rust. What I do is if the machine isnt going to be used for sometime, especially during the winter, is remove the roll from the machine and store it on a shelf in my home. I would especially do this with fluxcore wire, because I have heard that core material can draw moisture and make the wire useless.

By the way, which machine do you have? If it is a HH 175 or larger, one of these days you should give solid wire and either C25 or Co2 shielding gas a try. If you ever try solid wire, you will never want to use the self shielded fluxcore wire again. I even use it outside. I just take the time to set up a good wind block.

Anyway, I would save myself some money and get the larger roll. Just store it properly and you shouldn' t have any problems.

[Will]

I agree, rust should not be an issue with the big spools. I use both .023 and .030 so a spool can last a long time. Even with the handling when I put the partial spools on and off, I have not seen any rust, and I am not taking any special storage precautions.

[Hobart Expert Rock]

HI MARK..........THE FLUX CORED WIRE'S IN OUR MACHINES TEND TO SIT ON THE MACHINES FOR AWHILE...........SOME RUST WILL OCCUR WHICH IS NORMAL.......HOWEVER IT TAKES QUITE A BIT OF TIME FOR THIS TO HAPPEN IN A TYPICAL CLIMATE....... ROCKY D. HEY I LIKE THE PICTURE OF THE OLD ORIGINAL HANDLER. I PURCHASED ON OF THESE WHEN THEY FIRST COME OUT......I ALSO LIKED THE WAGON......I THINK I USED ONE JUST LIKE IT FOR AWHILE...............ROCK..............SSCOTT@MILL ERWELDS.COM..