Fusion Gun.....No More......Thanx BRAND X !!!
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  1. #1
    Join Date
    Dec 2011
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    951

    Fusion Gun.....No More......Thanx BRAND X !!!

    I did the Tweco tip/nozzle mod to the Fusion 180 gun on my TA 181i Fabricator. First thing is to pull out the connection at welder. The little silver screw needs loosened and then the brass piece with the liner will pull out......6 inches was enough.
    I then took the gun to the bandsaw and cut just ahead of the nozzle threads.
    Using an m M9 x 1.25 tap I threaded into the gun about an inch. The hole in the gun worked fine with the tap. Lots of oil and constant clean out of hole and tap are needed.
    I then cut the gun back behind the threads. Not needed but looks better and leaves less gun uncovered by rubber.
    Here I am finished. Pretty simple. The part I used.....diffuser.....tip.....and nozzle are all from a Lincoln Magnum 100 gun I had laying around. The length on the liner worked also in this case. The tap I borrowed from work. One important thing ....I need to cover the bare part of the gun just behind the diffuser.

  2. #2
    Join Date
    Jan 2004
    Posts
    1,575

    Re: Fusion Gun.....No More......Thanx BRAND X !!!

    I made the modification by disassembling the gun handle, so that I could remove the conductor tube from the gun lead. This allowed me to remove the rubber sleeve off the conductor tube. Once the gun handle is apart, all you have to do is loosen a set screw to separate the conductor tube from the gun lead
    ESAB Migmaster 250
    Hobart Ironman 230
    Multimatic 215
    TWECO Fabricator 181i & 211i
    HH125EZ - nice little fluxcore only unit


    Maxstar 150 STH - very nice

  3. #3
    Join Date
    Jan 2005
    Posts
    3,958

    Re: Fusion Gun.....No More......Thanx BRAND X !!!

    Quote Originally Posted by Dan View Post
    I made the modification by disassembling the gun handle, so that I could remove the conductor tube from the gun lead. This allowed me to remove the rubber sleeve off the conductor tube. Once the gun handle is apart, all you have to do is loosen a set screw to separate the conductor tube from the gun lead
    That's the way I did it too, but drilled the end out on my drill press.(because I could) I also put in a ATT 42-3035-15 liner at the same time. The 211i did well with those two mods.. On the 250 fusion gun there is a set screw in the handle,and it's holds the liner from being in a bind when installing the Fusion tip. I did not notice it with the 180 gun. Nothing stopped the liner from coming out anyway.. It can be accessed through the handle on the 250.. Now the two guns I use on the 252i take the same consumables. (fixed nozzle, and #14 Tweco tips)
    Esab 2200i-TA34
    Esab 160i caddy
    Thermal Arc LM-200 Lincoln feeders
    Thermal Arc Pee-Wee 85s
    2-Thermal 60i- 3phase (Beast)
    Thermal 38XL
    Klutch P-300i/ 120 volt













    If I agreed with you, we'd both be wrong!

  4. #4
    Join Date
    Dec 2011
    Posts
    951

    Re: Fusion Gun.....No More......Thanx BRAND X !!!

    My 211i came with a Tweco 220 mig gun. The 180 fusion gun did need drilled out the M9 x 1.25 tap worked just fine with the existing size hole.


    Is there much to change out the rubber over the conductor tube on the 180 Fusion gun?

  5. #5
    Join Date
    Jan 2005
    Posts
    3,958

    Re: Fusion Gun.....No More......Thanx BRAND X !!!

    Mine might of been the same gun, Either way, same exact process between the small fusion guns..Cable size is different, nothing else.. I just pulled the Rubber up farther, and it was fine. Leaving the o-ring on the neck will not hurt anything.I just used the correct drill size for the tap, that's all..
    Esab 2200i-TA34
    Esab 160i caddy
    Thermal Arc LM-200 Lincoln feeders
    Thermal Arc Pee-Wee 85s
    2-Thermal 60i- 3phase (Beast)
    Thermal 38XL
    Klutch P-300i/ 120 volt













    If I agreed with you, we'd both be wrong!

  6. #6
    Join Date
    Apr 2016
    Location
    CA
    Posts
    6,120

    Re: Fusion Gun.....No More......Thanx BRAND X !!!

    Any pics of how the diffuser looks threaded into the neck with out the nozzle covering it ?
    Lincoln, ESAB, Thermal Dynamics, Victor, L-tec, Miller, Dewalt, Makita, Kalamzoo. Hand tools, power tools, welding and cutting tools.

  7. #7
    Join Date
    Dec 2011
    Posts
    951

    Re: Fusion Gun.....No More......Thanx BRAND X !!!

    I will try and get a pic up tonight.
    Last edited by rahtreelimbs; 10-27-2016 at 01:27 PM.

  8. #8
    Join Date
    Dec 2011
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    951

    Re: Fusion Gun.....No More......Thanx BRAND X !!!

    Hope this helps......


  9. #9
    Join Date
    May 2014
    Posts
    25

    Re: Fusion Gun.....No More......Thanx BRAND X !!!

    I dont have a bandsaw anymore would a hacksaw blade be fine if i debur it after?

  10. #10
    Join Date
    Apr 2016
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    CA
    Posts
    6,120

    Re: Fusion Gun.....No More......Thanx BRAND X !!!

    Looks good rtl thank you.
    Lincoln, ESAB, Thermal Dynamics, Victor, L-tec, Miller, Dewalt, Makita, Kalamzoo. Hand tools, power tools, welding and cutting tools.

  11. #11
    Join Date
    Apr 2014
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    30

    Re: Fusion Gun.....No More......Thanx BRAND X !!!

    I cut mine with an old school manual pipe cutter, worked like a charm!

  12. #12
    Join Date
    Dec 2011
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    951

    Re: Fusion Gun.....No More......Thanx BRAND X !!!

    This is one of those cheap, easy and really effective mods that really works!!!

  13. #13
    Join Date
    Jan 2008
    Location
    Richmond, Virginia
    Posts
    6,945

    Re: Fusion Gun.....No More......Thanx BRAND X !!!

    Quote Originally Posted by rahtreelimbs View Post
    ... one of those cheap, easy and really effective ...
    Reminds me of a gal lived up the street when I was in Thailand. She was in a house that had a long line in front on payday.
    "USMCPOP" First-born son: KIA Iraq 1/26/05
    Syncrowave 250 w/ Coolmate 3
    Dialarc 250, Idealarc 250
    SP-175 +
    Firepower TIG 160S (gave the TA 161 STL to the son)
    Lincwelder AC180C (1952)
    Victor & Smith O/A torches
    Miller spot welder

  14. #14
    Join Date
    Dec 2011
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    951

    Re: Fusion Gun.....No More......Thanx BRAND X !!!

    There ya go !!!

  15. #15
    Join Date
    Apr 2016
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    CA
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    Re: Fusion Gun.....No More......Thanx BRAND X !!!

    Hey ya'll I think I want to try this mod and am wondering what is the main difference between the 11 contact tips and the 14 contact tips. The spool gun I have currently uses size 11 contact tips so I'm thinking if the same diffuser will work on these guns then I Have an extra neck I can modify for the fusion 250 gun I recently purchased. It would be cool to be able to use all the same consumables for both mig & spool guns if/when I see major improvements from this mod.
    Last edited by N2 Welding; 11-02-2016 at 03:55 PM.
    Lincoln, ESAB, Thermal Dynamics, Victor, L-tec, Miller, Dewalt, Makita, Kalamzoo. Hand tools, power tools, welding and cutting tools.

  16. #16
    Join Date
    Mar 2014
    Posts
    13

    Re: Fusion Gun.....No More......Thanx BRAND X !!!

    I used a Tweco 52 gas diffuser. 21/64 drill bit and 3/8-24 tap. I cut mine off at the o-ring recess with a tubing cutter like someone else mentioned, then buffed it down with a file. It will put you into the inside radius a little, but really clean looking. Also, if you want to use Magnum 100 consumables, just get Lincoln gas diffuser S20277. Same 3/8-24 thread, but uses 100l consumables. Might have to trim you liner thoughName:  57094224731__DDD7ED37-89CD-4E4E-874A-D2494DF8BEC0.jpg
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  17. #17
    Join Date
    Oct 2015
    Location
    NW New Jersey
    Posts
    303

    Re: Fusion Gun.....No More......Thanx BRAND X !!!

    M9x1.25 ?
    Airco 250 ac/dc Heliwelder Square wave
    Miller Synchrowave 180 sd
    Miller Econo Twin HF
    Lincoln 210 MP
    Dayton 225 ac/dc
    Victor torches

  18. #18
    Join Date
    Mar 2014
    Posts
    13

    Re: Fusion Gun.....No More......Thanx BRAND X !!!

    Quote Originally Posted by albrightree View Post
    M9x1.25 ?
    No,3/8-24 thread. If you use the M9-1.25, you're limited to just the Magnum 100L consumables. If you thread it 3/8-24, you can use a 52 diffuser,or use the S20277 Lincoln diffuser that allows you to use Magnum 100L consumables. Worst case scenario, you'll have to swap the liner out. I would anyways, because I cut mine off at the o-ring recess. Look at my pics,the small diffuser is the Magnum 100 consumables,and the big one is the 52 diffuser with the 14 series consumables. Your machine puts out 215+ amps depending on the model. At some point you're gonna want options to go bigger without buying a new gun. Also,the Magnum 100 gun will fit your machine, you'll just need an 8-pin plug for it


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  19. #19

    Re: Fusion Gun.....No More......Thanx BRAND X !!!

    Did something similar with my Binzel gun, didn't like the slip-on, never centered and too deep recess. I used Lincoln 100/tweco/HTP.. diffuser, same thread at both ends (part number 10949).
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    A few options for the nozzles, 21-50, 21-37, 21-62, and 21-50f, 21-37f, 21-62f....

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    Now I have the tip centered, flashed and fixed.


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  20. #20
    Join Date
    Jul 2012
    Posts
    387

    Re: Fusion Gun.....No More......Thanx BRAND X !!!

    What are the reasons for doing such a switch?

  21. #21
    Join Date
    Mar 2014
    Posts
    13

    Re: Fusion Gun.....No More......Thanx BRAND X !!!

    Quote Originally Posted by Rock knocker View Post
    What are the reasons for doing such a switch?
    Cheaper more readily available consumables. The flux core nozzle I bought for my fusion gun when I ordered my esab rebel was apparently a fluke. The nozzles I bought for another fusion gun were just fine though. The fusion flux core nozzles are expensive for what they are,compared to standard tweco consumables


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  22. #22
    Join Date
    Jul 2012
    Posts
    387

    Re: Fusion Gun.....No More......Thanx BRAND X !!!

    Thanks.

    My 181 came with a 180 Weldskill gun. I don't know if that is the same gun with a different name, but since all I do is MIG I should be just fine, correct?

  23. #23
    Join Date
    Jul 2008
    Posts
    13

    Re: Fusion Gun.....No More......Thanx BRAND X !!!

    I did the same thing and used Tweco number 2 consumables to my first welder in the early '90s. It was a 225 Century with a mini mig gun and a few years later I rigged up a SG 100 spool gun for the same machine and changed it to the same consumables. Price and availability of parts is why I did it. Glad to see others doing the same.

  24. #24
    Join Date
    Mar 2014
    Posts
    13

    Re: Fusion Gun.....No More......Thanx BRAND X !!!

    Quote Originally Posted by Rock knocker View Post
    Thanks.

    My 181 came with a 180 Weldskill gun. I don't know if that is the same gun with a different name, but since all I do is MIG I should be just fine, correct?
    Oh absolutely! All I weld is flux core,and the flux core nozzles for the fusion gun are expensive. That and the first one had was faulty, the contact tip pulled through the nozzle. That, and I enjoy modding to use different than original parts


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