[caltom]

I’ve been looking at converting my Tweco fusion 220 mig gun to take standard consumables for the Tweco #2 gun. The neck is just a copper tube. I think I can cut off the external threads for the Fusion nozzle, then thread the inside 3/8-24 for a #52 diffuser and then use #22 nozzle, #14 tips and #32 insulator. My local hardware store has all the parts except the insulator.

The problem I’ve been having with the fusion system is the nozzle and diffuser are made together, so it can’t be cleaned very well. It accumulates a lot of crap and splatter inside, shorts the diffuser to the nozzle, and plugs up the gas flow. I also think the Fusion tips don’t seat well into the diffuser and depending on gun angle/lead twist, the liner pushes them out and they make poor contact. Another benefit is the standard consumables are cheaper than the fusion stuff.

Am I missing something on doing this? It seems simple.

The pictures are of a nozzle I drove the diffuser out of. A lot of spatter fell out it.

[caltom]

Yep it was that easy. $38 in parts. It welds very well, much less dependent on gun position and lead twist.