How To Convert Gas Mig Welder To Gasless (Easy 7 Steps To Follow)

Mig welders are easy to use and great for welding. Mig welders need gas cylinders and extra accessories that many welders find burdensome. Also there is an option to go for flux core welding which is akin to mig welding but uses no gas for welding.

You can convert a mig welder to a gasless mig welder. It saves you money and provides comfort. A gasless Mig welder has multiple advantages: it is portable, lightweight, and faster than stick welding.

Here we will guide you to learn the perfect way of transforming your gas mig welder to gasless.

How To Convert Gas Mig To Gasless
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Can You Really Convert Gas Mig Welder to Gasless Welder

Though it is a little bit tricky to convert a gas Mig welder into gasless, you can do it.

It generally requires you to exchange the output cables with gasless cables from the internal part of the welder where the rectifier is located.

However, it is initially crucial to determine whether it is compatible to convert or not. Some gas Mig welders have fixed construction that can’t be converted.

How To Convert Gas Mig Welder to Gasless Mig Welder

Converting a gas Mig welder to a gasless Mig welder requires you to follow some necessary steps. Here are they:

How To Convert Gas Mig Welder to Gasless Mig Welder

Converting a gas Mig welder to a gasless Mig welder requires you to follow some necessary steps. Here are they:

  • Step-1: Cleaning the Metal

Before converting your gas Mig welder into a gasless Mig welder, you need to clean the metal part properly to make the task easier. Just use an old brush to get rid of dirty metals, dirt, and debris from its surface.

  • Step-2: Select the Right Welding Wire

Gasless MIG welding requires flux-core welding wire. Choose a flux-core wire suitable for your application. Ensure that the wire diameter matches the specifications of your MIG welder.

  • Step-3: Remove Gas Cylinder and Regulator

Disconnect the gas cylinder and regulator from your MIG welder. Since you won’t be using an external shielding gas, these components are no longer needed for gasless welding.

  • Step-4: Adjusting the Setting of the Gas Mig Welder

Now, you need to select the level of the ideal amp you will need for completing your particular project. Since almost all Gas Mig welders come up with a control panel. Adjusting these settings are easy-going. You need to change the settings as per the material you prefer for welding. In addition, considering the metal thickness level is also important.

  • Step-5: Install Flux-Core Welding Wire

Replace the solid welding wire in your MIG welding gun with the flux-core wire. Ensure that the wire is threaded through the welding gun and properly secured.

  • Step-6: Adjust Wire Feed Tension

Flux-core wire may require different tension settings compared to solid wire. Adjust the wire feed tension according to the manufacturer’s recommendations for the flux-core wire you are using.

  • Step-7: Switching On the Machine

After inserting the wire in both power sources and the machine, carefully turn on the machine. Going through the instruction manual, you will have a decent idea to learn the perfect way of wire loading.

  • Step-8: Selecting Current Strength

The next task is determining and selecting the appropriate strength of the current. The higher the current level you choose, the more powerful it will be.

Generally, you want to select a considerable amount of current if the metal is pretty thick. Compared to aluminum, steel & chromoly welding needs a higher level of current.

  • Step-9: Changing the Polarity

Here comes the most important part. Verify that the welding machine is set to the correct polarity for flux-core welding. Typically, gasless MIG welding requires a DC electrode positive (DCEP) polarity.

Changing their polarity will be necessary if you replace the wire. Generally, you need to swap the output cable at the rectifier from the internal part of the welder.

  • Step-10: Finishing Up

Now, your gas welding machine is converted into a gasless welder machine. You can now test it using an unnecessary metal part.

Safety Measures To Maintain In Converting Process

Since you are working with electrical items, ensuring optimal safety is crucial to avoid facing any hazardous situation.

Generally, gas Mig welders can produce fumes and excessive flushing lights while welding.

So, don’t forget to wear a decent pair of high-quality protective gloves and a welding helmet to keep yourself out of danger.

Besides, you should be cautious while touching wires and make sure you have adequate knowledge on wire panel connection.

Can You Convert Gasless Mig To Gas Mig

Yes, you can obviously convert your gasless Mig welder to Gas Mig welder by following the inverse approach.

But you need to maintain the ideal level of voltage and heat constantly. In addition, choosing the right wire is also important to provide appropriate current strength.

Additionally, you need to use filler metals to prevent porosity issues. Don’t forget to clean the welding material between passes.

What Are The Differences Between Gas Mig and Gasless Mig Welding

  • A noticeable difference exists between the machines for gas and gasless welding. The polarity settings are different in gasless welders than mig welders. For example, a gas Mig welder features a positive (+), single torch feed, while the flux core welder has a negative (-) torch feed.
  • Gas mig welder uses an external shielding gas, typically a mixture of argon and carbon dioxide or argon and oxygen, to protect the weld pool from atmospheric contamination. While gasless welders use no external gas. It uses flux core wire to protect the weld puddle from contamination instead.
  • Gas mig welders typically require a gas cylinder, making the setup less portable. While Gasless MIG Welder can be more portable since it doesn’t rely on an external gas cylinder.
  • Gas mig welder generally involves additional costs for purchasing and refilling gas cylinders. While gasless Mig welder may be more cost-effective initially, as it eliminates the need for an external shielding gas.
  • Another noticeable difference is fumes & smokes. A huge volume of smoke and fumes is produced from a gasless Mig welder, while the mig welder produces a tiny portion of fumes or nothing at all.
  • Gasless Mig welders are more appropriate for outdoor ventilated areas, while gas Mig welders appear perfect for indoor areas.
  • You have to spend more time cleaning and preparing the metal for gas Mig welders than gasless Mig welders.

Which One Is Good For Perfect Weld (Gas Or Gasless Mig Welding)?

Though both options are good, requirements vary from each other. Here are all the main reasons behind choosing a particular one.

  • Your Job Location

When you are working outside areas like your firm house or any rural areas, choosing the gasless Mig welder is better. But working in any indoor place, gas Mig welder is sufficient. 

  • Type Of Metal

Gasless Mig welders are a little bit risky to work with for some materials. For example, if you are welding stainless steel or aluminum, it is best to use a gas Mig welder to ensure optimal safety.

  • Portability

For using a gas-shielded Mig welder, you must be prepared to carry the gas cylinder where you want to weld. If moving the gas cylinder from one spot to another seems tedious, you may use a gasless Mig welder.

  • Cost

Compared to gas Mig welders, gasless Mig welders are a little expensive as you have to use a gas cylinder in addition to a wire spool.

Frequently Asked Questions

1. Can you use gasless wire in a gas MIG welder?

Yes, you can use gasless wire in a gas MIG welder by simply swapping out the solid wire and adjusting the settings for the flux-core wire.

2. Is gas better than gasless for MIG welding?

The choice between gas and gasless MIG welding depends on the application. Gas provides cleaner welds, while gasless is more portable and suitable for outdoor use.

3. Can I use flux wire in a MIG welder?

Yes, flux-core wire is designed for MIG welding. It contains a flux coating that generates a protective gas during welding, eliminating the need for an external shielding gas.

4. Which is better, MIG or flux?

The choice between MIG and flux-core welding depends on the application. MIG offers cleaner welds with external shielding gas, while flux-core is more versatile for outdoor and portable welding.

5. Can you weld Aluminum with gasless MIG?

Gasless MIG welding is not suitable for aluminum. For aluminum welding, a MIG welder with appropriate shielding gas is recommended.

6. What are the benefits of gasless MIG welding?

Gasless MIG welding is portable, suitable for outdoor use, and eliminates the need for an external shielding gas. It’s cost-effective and versatile for various applications.


When it comes to choosing a welder, we often feel confused about whether to choose a gas or gasless version. Since professional people handle a wide range of projects, they will need both types of welders as per the work type.

Knowing how to convert gas Mig welder to gasless can help you utilize one type of welder for another. However, the procedure may appear a little bit tricky if you don’t have enough electrical knowledge.

Another option you can go for is to choose a multi-process welder. Multi purpose welders come up with different welding techniques within a single machine. It saves money and provides flexibility to use different methods.

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