Another Millermatic 200
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  1. #1
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    Another Millermatic 200

    Hello, I recently bought a Millermatic 200 that I feel was a pretty good deal. Of course its 25 years old (JJ273573) and could use some cleaning up. the face plate is in fairly good shape with the exception of the SKP-35 which has what looks like automotive red oxide primer spattered on it. I think a good cleaning with simple green, touch up the black and a coat of Krylon satin clear will make it look new again. The rear panel seems to be original paint but the top, sides and door have been repainted and it shows.

    Now my questions.
    1. Decals, I have found 3 different decals for the sides. Can someone tell me if the ones on mine are the correct ones? The decal on the inside of the door has white paint on the lower section by the hinge. I don't know how I'm going to get that off.

    2. Cleaning the inside. There is quite a layer of dirt, grease on the bottom and dust on the components inside. I can take a blow gun and clean the dust off of the components but what about the bottom? I had read that you can pressure clean the insides of the welder which I find hard to believe because of the electronics. Plus all the grease would splatter onto those electronics. What method do you use to clean all the crap from the bottom?

    3. I'm also going to have to find some cover screws there's a few missing.






    You can tell it was repainted but are those the correct decals?



    Relatively clean except for the bottom.



    Caps all look good, the one just has a wrinkle in the white plastic cover, it's not melted.

  2. #2
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    Re: Another Millermatic 200

    Quote Originally Posted by Doug_ View Post
    Now my questions.
    1. Decals, I have found 3 different decals for the sides. Can someone tell me if the ones on mine are the correct ones?
    No they are not. Those decals are later/current logo. Originals are 5" diameter whereas typical aftermarkets are either 4" or 6".

    These are the correct 5" version for your unit.
    Name:  Roughneck 2E 032.jpg
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    Member 7A749 (Steve) used to have these and may still have some available.

    Quote Originally Posted by Doug_ View Post
    2. Cleaning the inside. There is quite a layer of dirt, grease on the bottom and dust on the components inside. I can take a blow gun and clean the dust off of the components but what about the bottom? I had read that you can pressure clean the insides of the welder which I find hard to believe because of the electronics. Plus all the grease would splatter onto those electronics. What method do you use to clean all the crap from the bottom?
    1) Spray degreaser and wash off with hose.
    2) Pressure washer adjusted for fan spray and lower pressure if so adjustable. Electronic PCBs are sealed and I clean with soap and water all the time. Also pressure wash generators and welders regularly. Blow dry real good with compressed air. A couple hours in direct sunlight if desired will assure a properly dried out unit.

    Quote Originally Posted by Doug_ View Post
    3. I'm also going to have to find some cover screws there's a few missing.
    Pay a visit to your local hardware/fastener supplier.

    Quote Originally Posted by Doug_ View Post
    Caps all look good, the one just has a wrinkle in the white plastic cover, it's not melted.
    Can't tell from the photo but that wrinkle can be a sign of damage, overheating or internal issue. Only way to properly test a capacitor is with a capacitor tester and FYI, caps do have a finite life. On a 25 year old machine, one might want to consider changing them soon especially if it's going to be used frequently. Replacements can often be found for under $20/each.
    Last edited by duaneb55; 04-14-2013 at 02:56 PM.
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  3. #3
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    Re: Another Millermatic 200

    duaneb55 Thank you so much for the help you have sent me in the right direction. I used one of these MM200's at work starting in 1988 and always wanted one. Now that I've got this one I want to bring it back to life. I gave it a short test before I bought it and it did work although I didn't get to use it for a long period that day.

  4. #4
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    Re: Another Millermatic 200

    Thanks 7A749 I'll make sure I go through the contactor after I wash it. You and Duane have been a big help. I'll get in touch

    I guess by looking at mine and looking at others on line and from the info I got here I'm a little confused. I'm now thinking mine might have been put together from parts. The model number on the front face plate is JJ372573, this number is invalid on the Miller site I do however have the OM-1303P manual effective with Serial KA898403, KA refers to year 1990 and my JJ refers to 1988. If you look at the face plate on mine it has the newer logo(circle with 3 hash marks and squared off letters), I also have the black plastic latches on the side for the spool cover, not the thumb screws as shown in the manual and in the photos I've seen of 200's with the 5" round decal on the side. I do have one fuse on the front instead of 2 circuit breakers.

    How new are the black lined decals with the model number in them?

    Sorry if I'm trying over engineering this subject.
    Thanks again

  5. #5
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    Re: Another Millermatic 200

    Quote Originally Posted by 7A749 View Post
    What are you referring to about the black decals? The faceplate? Black face machines are usually indicative of later model units, but again, there's no absolute cutoffs. They produced same model year units with both white & black faceplates on them. I think burning out on hand stock played a part in that, but I'm not certain,

    I wouldn't sweat it. Get it cleaned up & running. They're great little machines.

    IMHO of course
    Here is a picture showing the black decal

    And you're right I'm not going to sweat it. Thanks again 7A749.
    Attached Images Attached Images  

  6. #6
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    Re: Another Millermatic 200

    I did a little work on the welder today. I used simple green and washed down the frame and panels. I made sure I kept the soap and water off of the electronics or at least I didn't hose them down. I blew everything down and let it sit out in the sun. I still need to bang out some dents, sand and paint the covers and apply new decals. I had no idea that the hose to the regulator was green.

  7. #7
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    Re: Another Millermatic 200

    It looks clean enough to me, just plug it in and weld.
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  8. #8
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    Re: Another Millermatic 200

    One way to test a cap bank is done while welding. Get a nice soft arc going at around 18 volts. The pull back the gun to a long stick out. A good cap bank will keep the arc going even with a long stick out. A weak cap will cause the arc to pop out about the time you start to lift and you can only keep the arc going with just off the tip.

  9. #9
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    Re: Another Millermatic 200

    Doug,

    This is my resto on a JD serial number 1983 machine. It may help you. The color was correct for my year.

    http://weldingweb.com/showthread.php...ght=Mm200+REDO
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  10. #10
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    Re: Another Millermatic 200

    Quote Originally Posted by Drf255 View Post
    Doug,

    This is my resto on a JD serial number 1983 machine. It may help you. The color was correct for my year.

    http://weldingweb.com/showthread.php...ght=Mm200+REDO
    Wow that turned out great. I think I'll do what you did and take the panel down to the automotive paint supplier and let them match it. the insides are in pretty good shape.

    Only thing is one of the previous owners spray painted white paint on the inside of the hinged cover and got some on the decal. I don't know how I'm going to clean that up.
    Last edited by Doug_; 04-18-2013 at 12:39 PM.

  11. #11
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    Re: Another Millermatic 200

    Quote Originally Posted by Doug_ View Post
    Wow that turned out great. I think I'll do what you did and take the panel down to the automotive paint supplier and let them match it. the insides are in pretty good shape.

    Only thing is one of the previous owners spray painted white paint on the inside of the hinged cover and got some on the decal. I don't know how I'm going to clean that up.
    If you take your time with some mineral spirits and a rag, you may be able to get it off without damaging the decal.
    TA Arcmaster 300
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  12. #12
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    Re: Another Millermatic 200

    I'll have to give that a try. I've got some mineral spirits out in the garage. Thanks Drf255

  13. #13
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    Re: Another Millermatic 200

    Thanks,
    The other day I brought it outside and washed it down. I hit the face plate with simple green and it turned some places white there was also some packaging tape residue that I didn't see. I'll take the face plate off and get it straightened out. I think that there are about 7 pop rivets that I'll have to drill out and a selection of bolts. The wire speed knob has a set screw but I'm not sure about the range selector. I think I read somewhere that there's a roll pin..

    As I was taking the rear panel off to do some cleaning I broke one of the fan mounting studs. The nut twisted the stud and broke it. What I did to fix it was to thread the broken off stud almost all the way to where it bends. I'm going to pick up a rod coupling nut 1/4 20 cut the stud a little and thread the coupling nut on and then screw a stud into the end of the coupling nut, slip the panel on and run a nut on the repaired stud. You shouldn't even be able to tell it was repaired with the panels on.

    I found what I think is an old Miller logo. I'm using it as my avatar. It was on a reproduction welding helmet. I copied it but don't know if I used the correct font.

    Again Thanks for all the help you've given me.
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  14. #14
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    Re: Another Millermatic 200

    Doug, there are repro Miller logos on eBay pretty cheap. My avatar is what they look like.

  15. #15
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    Re: Another Millermatic 200

    Quote Originally Posted by cope View Post
    Doug, there are repro Miller logos on eBay pretty cheap. My avatar is what they look like.

    Thanks cope , I'll have a look. I can cut vinyl, I've got a plotter but I am unable to print and contour cut. If I layered the vinyl I'd have to settle on the colors offered by the vinyl manufacturers.

  16. #16
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    Re: Another Millermatic 200

    Quote Originally Posted by Doug_ View Post
    Thanks cope , I'll have a look. I can cut vinyl, I've got a plotter but I am unable to print and contour cut. If I layered the vinyl I'd have to settle on the colors offered by the vinyl manufacturers.
    6" http://www.ebay.com/itm/Miller-Elect...item48465a1019

    8" http://www.ebay.com/itm/1-Pair-Of-Mi...item2a20dc2b13

  17. #17
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    Re: Another Millermatic 200

    Well I worked on the welder a little today. Took the block off plate for the SKP-35 and did a test with Krylon Satin Clear. I got it on a little heavy but all in all it looks a lot better.



    You can see where someone sprayed white paint inside the lid. Under the white I found black. I took some lacquer thinner on the white and you can see where it started to take the white paint off. I'll work on it a little more this week.

  18. #18
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    Re: Another Millermatic 200

    I had a little bit of a setback today. I took both the main faceplate and the faceplate from the SKP-35 off of the machine today and tried to clean them up. The face plate from the SKP-35 cleaned up well. I used some lacquer thinner, testing it first to see what it would do. Then when I painted it with the Krylon Clear Satin it clouded up. So i quickly removed the Krylon the best I could. It looks better than it did when I started but there are flat spots in the finish. I tried a little lacquer on the main faceplate and it took it right down to the aluminum. I'll touch it up but I'm afraid to use the Krylon on it. I don't want it to cloud up like the SKP-35 faceplate did.


    Here is the SKP-35 face plate before. There is a lot of over spray on it.


    Knobs from the SKP-35 two cleaned up two to go.


    Main faceplate I need to touch it up and clean it.

  19. #19
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    Re: Another Millermatic 200

    Well just got back in town after a weeks vacation.



    Before and after of the face plate. It will look better when I get it all dressed with the plugs, dials and switches. My shadow in the new clear coat.



    Took the Voltage adjustment knob/pointer and hit it with some steel wool then gave it a coat of clear.



    When I took the rear panel off to clean it I broke one of the cooling fan mounting studs off. I threaded the mounting stud back a ways and cut it off. I used the section I cut off and Loctited in the long nut along with a jam nut.



    Here it is assembled and ready to mount back in the rear panel.



    All back together for now I have the front panel off and might have to take the rear off again later.



    Sat down at the computer and redid one of the logos. All I had to go by was a photo I took off of the internet. I used the color pick tool for the two lines under the letters.
    Last edited by Doug_; 05-15-2013 at 05:23 AM.

  20. #20
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    Re: Another Millermatic 200

    Looking awesome Doug. Keep the photos and updates coming.
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  21. #21
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    Re: Another Millermatic 200

    Thanks Guys, I'm having a lot of fun with it.

    On the satin finish fogging up I thought it was because I used lacquer thinner to clean the faceplate I thought the fumes were the cause.

    I had tried using a sharpie to touch it up and It didn't blend in to well. That was on the SKP-35 block off plate so I thought it wouldn't look so good on the faceplate. maybe I should have used it. but I think it's to late now.



    I stopped by the automotive paint supply store today, picked up the things I needed to paint the sheet metal and had them match the front panel seeing it was the cleanest behind the faceplate.



    While removing the front panel I broke one of the terminals on the fuse to the pilot light, so I picked up a few replacements.



    Also figured I'd replace the yellow HI/LO plugs also.

  22. #22
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    Re: Another Millermatic 200

    A small amount of progress made today.



    I started on the sheet metal I took the panel from under the spool door, hammered out a few small dents, used some filler and primed it.



    Got the edges done around the front panel. The face plate will cover most of this panel so I'm just going to paint the edges.

    My 1/4" 20 x 1/2 flange head bolts came the other day also.

  23. #23
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    Re: Another Millermatic 200

    Looks great Doug.
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  24. #24
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    Re: Another Millermatic 200

    Quote Originally Posted by Drf255 View Post
    Looks great Doug.
    Thanks Drf255, it's been slow but a lot of fun. I'm waiting on a couple of other things before I continue. I'll keep the thread updated when I get some more accomplished.

  25. #25
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    Re: Another Millermatic 200

    Well it's been a couple of weeks since I last posted. But I got some more work done on the welder. I started sanding , straightening and priming the main cover. There were some small dents in the top and some of the corners were bent.


    Here's a view of the long side. Pretty much ready for paint.


    Here's the short side I might still have a little bow in the bottom edge.


    And last the top. It was the worst, two layers of chipped paint. I took it down to bare metal.

    I also took the sides down to one layer of paint. I don't know what kind of paint was used for the second coat but it sure clogged up the sand paper. I'm glad I got all of it off before I primed. Well that's it for this up date.

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