Airco Dip-Pak 200 feed roll problem

[Eyecatcher]

I have an old Airco mig with a tweeco gun. I know it's old, but it's been a real workhorse, and I can't afford to replace it, so need to find a fix. Right in the middle of a project where I really need it.
It just won't feed wire! Replaced the liner, tip etc. Cleaned the feed rolls with carb clnr. Took the wire spool holder off and cleaned an lubricated. I have the tension on the spool axle backed way off. I thought this might be a rusty wire problem, but the wire looks pretty good, still copper coated (.035). The top roller is flat. The bottom roller has two grooves, one marked .045 the other .035. I have the bottom in front of me, if I bend the .035 wire around in the groove, it appears to fall flush with the surface of the roller. Doesn't it have to stand proud in order to be pushed? I understand that Airco is no longer in business, but somebody should have these replacement rollers, although I haven't been able to find any. I wander if taking this lower roller to a machine shop and having them turn a few thousandths off the OD
would make it push wire again. Anybody got any suggestions?

 

[yomax4]

Looks like you did all the right tests.. If you can somehow post a good close up of the feed roll, I may have one that you can have..

 

[Eyecatcher]

I'm no good with the picture thing, but I think I can pretty well describe it. Shaft size is 3/8" w/ keyway. OD is 1.375 width is 3/4". Has 2 grooves, .035 & .045. Only markings are .035 on one side and .045 on the other.

 

[CNC Dan]

is there a groove worn in the other roller? if there is, could you turn it arround?
if that doesn't work, i would go ahead and have the outside turned down a little. not too much though, the other groove might not be as worn.

 

[Arc weld]

It's possible Esab may have a drive roll to fit since they purchased the rights to some Airco machines. Profax might be another supplier of an aftermarket drive roll. It does sound like the drive roll is worn out. Might be able to look online. Is there any way to use a spacer and cut a new groove in the existing drive roll if you can't find a new one?

 

[Eyecatcher]

CNC Dan - The backside of the top roller has a drive gear machined on it, can't turn it around, but it appears to be smooth.
Arc weld - Because the drive roll has 2 grooves machined in it, you turn it around to use the other side, so would have to make it narrower then regroove.
There's an old timer has a retired weldshop business here in town, I'm gonna try and catch him today and let him look at the wire and the roller for his opinion.
I talked to the local Paxair dealer, he is also an Esab dealer, and he told me to bring the roller and he'd try to find me one. That's my second stop.

 

[Eyecatcher]

Just made it back from town. The old welder wasn't around, but did get to the dealer. He looked at the roller and the wire, and agrees the roller is worn out.
Anybody know where to get drive rollers for Airco?

 

[yomax4]

Ill dig through my stuff and see if I have one that matches your measurements.

 

[Eyecatcher]

Yomax, I hope you have one. I called Esab tech support, and he gave me p/n 2361-2377. said it was obsolete and unavailable. If you don't have one, looks like I've about beat this old horse to death. If I had any idea how far proud the wire was supposed to stand, I'd try to get this one turned down. Any idea?

 

[CNC Dan]

Yomax, I hope you have one. I called Esab tech support, and he gave me p/n 2361-2377. said it was obsolete and unavailable. If you don't have one, looks like I've about beat this old horse to death. If I had any idea how far proud the wire was supposed to stand, I'd try to get this one turned down. Any idea?

I would say that the groove is just a little deeper than the wire. Once the wire starts to slip, you stop using the welder, right? So I would go a minimum of .005"/side(.010" diameter) to as much as half the wire thickness per side.