Average Reviews:
(More customer reviews)I bought this machine (Hobart Handler 140) more than a year ago and have put it through its paces. It comes with the regulator, switch and hose so you only need the tank. Of course you can use flux core without the tank. Remember that you can get away with welding stainless with Argon but Trimix or an Argon/CO2 mix it recommended. I already had a helmet etc. so another $120 for a new full R40 Argon tank and I was MIG welding aluminum.
This is a fully functional MIG welder that runs on 115V (20 amps) current. It is well made and I haven't had any problems with durability or malfunctions, it is quite reliable in that respect. It is quite portable and I like the safety switch which is only live when you're actually welding. I also called support once (about the liner) and they were prompt and helpful. It does have one tiny annoyance that the door latch is made of plastic and doesn't usually latch properly, but since the door hangs down when closed anyway, it really doesn't matter.
I've welded various thicknesses of mild steel, Stainless and Aluminum with it and, for the most part, it has performed as advertised. I've also used both the 1lb roles and the 10lb rolls. One tiny problem, the spring is a bit too long on the small rolls and you have to put the lock nut for them on backwards in order to get low enough friction if you're using aluminum wire.
The machine does indeed weld 3/16" steel in one pass if you go very slow and have a smooth technique. If you are looking for something to weld heavy steel often, get a stick welder for half the money, or move to a 220 machine that will run heavier wire. With respect to heavy steel, I wanted this machine just for occasional smaller welds and it delivers there. On light sheet, it is like a glue gun for metal and fully in its element. It comes with Miller type tips but I actually prefer the shorter, flat nosed, Lincoln tips (which fit perfectly) for steel.
I've also welded a lot of stainless in the 12-18 ga range with it and it has been great at that as well.
Welding aluminum with this machine, as with every MIG except a spool gun in this power range, is a tedious process. On thinner material, you need to be very fast and very smooth. On thicker material, it can be really good IF you have good karma, think happy thoughts and have everything right - see below. If you're buying it primarily to weld aluminum though - this is not the appropriate class of machine for you. Depending on what you want to do, look for a 220 machine with intelligent speed control, or a TIG, or even a henrob torch or Al "brazing" rods. No matter how good you are, it is a pain and you'll end up with at least a few bird's nests per project with this machine.
How to weld heavier aluminum with this machine.
1. use a .045 tip. The machine only takes .030 aluminum wire and they recommend a .035 tip for aluminum but it isn't big enough. You really need to move to the .045 tip for aluminum or you aren't going to weld more than a couple of minutes before you start a bird's nest factory. Tips are only about a buck a piece.
2. Keep the gun hose very straight, especially on the machine end. This is tedious and difficult sometimes but it makes a big difference.
3. Use 5 series wire (e.g. 5356 - app. $5/lb. from several online sources like weldingsupply) instead of the 4043
that you see at home depot or harbor freight. Especially at the highest amperage, the 4043 is virtually unuseable in this machine (at least without a lot of headaches), even with the nylon liner. One annoying thing is that the 5356 is harder to feed near the end of the role and will be more prone to kinking. The 5356 does seem to require a slight bit more heat so you need to always push the weld and go slow on thicker material - ideally with the material flat. This machine rates at 5-10 amps more than the other machines on the market (140 vs. 130-135). It doesn't sound like much of an advantage but I read elsewhere that you can't get penetration with the 5356 in 115V machines and that just isn't true with this machine. I have a 450 gal 1/8" aluminum hot tub to prove it.
4. Use a nylon liner if you plan to weld a lot of aluminum. They are $17-$25, mine is from Miller. Also make sure that it is perfectly cut and aligned to the drive wheel.
5. Make sure that the aluminum is very clean.
In general, it is a good machine with good support and versatility. In its niche, it is a very good choice in relation to the other brands. I don't give it all the stars really only because they should be a bit more up front in their advertising that while it does weld aluminum, the machine (like others in its class) really isn't a great choice for that.
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Hobart 500500 Handler 140 115-Volt 25-to-140 Amp Gas/Metal/Arc Single-Phase Wire Welding PackageHobart's 500500 Handler 140 wire-feed welder offers industrial-quality performance on standard home circuitry and is expertly capable of running mild steel, stainless steel, flux-cored, and aluminum wires. Rugged and portable, this handy MIG welder's diverse applications for use at home, on farms and ranches, and for light fabrication projects make it ideal for machinery and car repair, fences and gates, grills and smokers, window security guards, signs, and more.
Features It's able to operate on 115- and 120-volt, 20-amp home circuits, and the broad output range of 25 to 140 amps allows for the welding of 24 gauge up to ¼-inch steel. Four output voltage settings with wire-feed tracking make the unit easy to set and adjust for different materials and thicknesses, and its integrated wire feeder with quick-release tension lever delivers positive feed with adjustable tension, which provides easy access for threading wire. The built-in contactor serves as an optimal safety feature that makes wire electrically "cold" until the trigger is pulled. Dual-groove drive rolls make it easy to switch between .023/.025-inch (0.6-mm) and .03/.035-inch (0.8/ 0.9-mm) wire.What's in the BoxOne Handler 500500 140 wire-feed welder, comfortable 10-foot (3-m) H100S2-10 gun; 10-foot (3-m) work cable with clamp; built-in gas solenoid valve and dual-gauge regulator with gas hose; spool hub assembly that accommodates 4- or 8-inch spools; sample spool of .03-inch (0.8-mm) self-shielding flux-cored wire; .03-inch (0.8-mm) contact tips; power cord with plug; weld set-up chart; and owner's manual with parts lists and installation, operation, and maintenance guidelines.
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