My first motorcycle was a Mini Bike – a Taco 44 kit that my neighbor and his dad decided was too much of a hassle to build. I traded my electric guitar for it.

My dad and I worked together to collect all the parts needed to build it.

Centrifigal chain drive clutches were popular then but a bit unreliable and noisy, so we engineered a belt drive system with a double pulley jackshaft, and chain drive to the rear sproket.

It was connected to a variable speed clutch, which was installed on a polished and chromed out, performance tuned Briggs & Stratton 5HP engine complete with a Tecumseh down draft carburator and straight pipe exhaust!

We turned the flywheel all the way down to the magnets, milled the head and made our own copper head gasket, as the OEM one was a thick layered sandwich design.

My dad organized a trip to Tijuana Mexico to have our 1969 Dodge Dart reupolstered. I invited two of my grade school buddies, Steve Maxwell and Eddie Fagg from Vista de Valle Elementry School in Claremont CA. Each of us brought our mini bike seats to have them reskined with custom material, button-tucked and finished off with some nice edge piping. The last thing we did before painting the frame gloss black was to redesigned the friction rear brake and custom foot pegs, which we had heliarc welded at Foothill Welding in Claremont, California.

When we picked up the parts from the shop, I was intrigued by the heliarc welds the guy had laid down, so I asked him a couple of questions, and he showed me how to make a few myself!

My friends thought it was all so cool – the bike – the welding. Before long, they had started calling me “Joe Welder”, and I guess it stuck !

I had a lot of fun on that old bike – it was the first time I really learned about engine modifications.

One night my Dad came home and saw me doing a trophy run down the alley behind the workshop. He said there was a long white flame streaming from the exhaust and it smelled like it was burning up.

When I explained how I had added some nitro to the high-octane AvGas, he knew I was ready to move up to a real motorcyle.

The other day when I was asking Joe Welder which TIG torches I should recommend when writing about the Nascar welders, and he could not stop talking about these two specific ones: the Modular and Micro TIG torches.  I was confused.  “So what’s so special about them?” I asked, naïve as I was.  In response I received what was, quite possibly, the longest answer in the history of welding and now feel like I know just about as much as anyone could ever know about these two torches.

The Micro TIG torch? It’s just like what its name implies; it’s tiny.  And that makes it perfect for any job where you need to get into a tight space.  It’s even capable of welding inside of a 5/8” diameter pipe.  It also has three interchangeable heads to choose from (45º, 90º and 180º angles) which make it almost impossible to find a job that this torch cannot do.

The Modular TIG torch?  Joe Welder’s FAVORITE.

He calls it “the most versatile torch on the market”.  Why?  Because you can choose from so many different torch heads at different angles and different amperages that it’s just about mind-boggling.  And you can also choose between air-cooled (WP-150) and water-cooled (WP-225) set-ups.

Kenneth from Pennsylvania asks Joe:

Do you have Weldcraft TIG Torch parts to fit a Miller DB20 water cooled TIG torch? Specifically a gas lens, collet and nozzle for .040? through .125″ diameter tungsten electrodes?

This question brings up a couple of points. First off, did you know that Miller and Weldcraft are related? Both are owned by the Illinois Tool Works (ITW). Currently all Miller TIG torches are sold as Weldcraft, taking advantage of the brand recognition of Weldcraft, a leader in the industry. Some earlier Miller torches were made by another company, but to quality standards.

Which leads me to point number two.

Most TIG torches parts are interchangeable. There are some exceptions, and certainly with some of the cheaper non-name brands you’ll find that the materials are not as good and the tolerances are, well, not tolerable…. But with quality brand names like CK, Diamondback, Lincoln, etc the parts should interchange.

Mark in Vermont asks:

I am running a Miller syncrowave 250 DX. Frequently welding cast aluminum, it pops and sizzles. I have always been looking for better cleaning techniques or a different tungsten to help get a stronger and prettier weld. There is always alot of black around the weld, and most times holes just “appear” in the weld. Any suggestions or tips to help?

That’s an interesting question — You can try a couple of things and see if it helps.

1. Use a gas lens collet body – this will improve the shield gas coverage, and allow you to run higher amperage while lowering the electrode and front-end parts operating temperature.

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David from Peoria (Arizona!) wrote in and asked:

….about “spray arc transfer MIG.” I tried it with my Miller 8VS and Syncrowave 200 (on CC mode). It sounded like TIG, but I ruined a tip & nozzle. Is this type recommended “at home,” or do you need a bigger multi-processor power source, and what are the advantages?

I quickly replied:
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I got a call today from Eric the maintenance foreman for the American Airlines Engine Repair Shop in Ft. Worth Texas. “Do you have the Monster nozzle in stock?” he asked.

When I said yes, he practically erupted with joy. “Man we have been looking all over for these things. They’re like gold around here.”

He told me they used to get a similar part but the quality was inconsistent, and the availability was too. He said, “We have a job to do, and we use these nozzles to TIG weld our Titanium and other special alloys that need repair.”

He went on to say that as the nozzles became scarce, they started making them in-house from a variety of materials — Phenolic, Ceramic and then settled on a CNC machined aluminum part that was ceramic coated. “The quality was great, but they take time to make and are expensive,” he said.

The Arc-Zone.com Monster nozzle will be a great replacement for them… and they can get on with the business they are in, welding specialized aerospace materials– not tools.

This is true of a lot of the quality purge gas accessories we sell at Arc-Zone. As a master fabricator you know you can build your own trail shield, or auxiliary gas welding nozzle…. but when you’re looking for consistency, and want to focus on your core business, it’s nice to have a supplier that can offer tools so you can Weld Like A Pro™.

I got a call from Fabio who is building an off-road rock climbing truck chassis (pictured right). He needed someone to help him set up his new TIG welder, so he called Arc-Zone.com.

Fabio had just moved back to Italy though he and his wife had spent the past couple of years living on Maui. He started the truck project there, bought some equipment and soon became frustrated with the lack of available products, and tech support. He had a brand new Miller Dyanasty 200 and needed all the goods it takes to properly weld a high-performance off-road truck. Considering the number of welding equipment manufacturers in Italy, I was surprised that Fabio was unable to find the info or qualified people to help him get what he needed.

Since that first call Fabio has placed several orders and we have them delivered to his local post office. And since I promised my wife Gina that I would take her to Italy one day, I hope I’ll be able to see Fabio TIG welding in person, and take a ride in his new off-road truck!

Lisa in Alameda emailed Arc-Zone.com with the following question:

I have a Miller Dialarc welder with a Weldcraft water cooled torch. I have been hooked up to city water and it’s worked fine for years. But I am moving my business to Klamath Falls, Oregon and my shop will get below freezing at night so I’ll need a self contained unit to cool my torch. Could you send me more information on just the cooling system/cool kit without the torch kit included as I have that….

Since Lisa already has the water-cooled torch, getting her set up with a water cooler should be pretty simple; all she’ll need is the cooler itself.

The water cooler that comes with the Cool Kit is our Tig-er cooler. It retails for about $500 plus shipping. It is a nice little cooler that runs 2 gallons. It’s solid and compact and would be a great addition to a small weld shop.

Lisa may need a water hose, and AW-431 fittings. She’ll also need the coolant which you can get from us, or from your local welding supply shop.

I’ve said it before but I love this industry and feel blessed that I’m able to meet so many interesting people and learn about what they are doing with metal fabrication.

I got a call from a Greg — he was in need of some technical info — specifically why his TIG hoses popped, and what he can do to keep it from happening. The power cable burst just outside of the handle. “I repaired it with some tubing, heat shrink etcetera, and it just popped again and started leaking,” he said.

His local supplier’s suggestion was to buy a whole new torch package — which he did– but that did not solve the problem. I talked him through the details of his TIG set up, specifically his connections to and from the power supply and the water cooler. I concluded that his coolant pump needed to be replaced.

We always have PROCON® pumps on hand and all the mounting hardware to connect directly to the welding industries most popular water coolers (from manufacturers like Bernard, Dynaflux and ITW). We also offer a nice refurbished coolant pump. It is much simpler, efficient and cost effective than trying to repair a pump yourself. Buy a refurbished pump, with all the fittings and mounting hardware and when you return your old pump core, we give you a 25.00 core credit!

Greg was relieved that we found the problem and I said we can ship your pump to you and you’ll have it tomorrow. “I need it today I got a job to do,” he said, then added, “and I want to come up and check you guys out!”

Turns out Greg is Greg Deering President of Deering Banjo Company located in Spring Valley, California about 40 miles from us.

We had a nice visit comparing notes about our early days as a start up company and how, due to the web we have connected with so many interesting people!

Deering Banjos “The Great American Banjo Company” is the premier manufacturer of banjos. These finely crafted instruments are played by some the best musicians worldwide. Obviously there is a lot of woodwork involved and apparently some of the brasswork is TIG welded! Check out the factory here:

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We’re starting a new regular feature on this site, Ask Joe™

Each week we’ll feature real questions from real customers, and answers from our own Joe Welder. Joe, aka Jim Watson, doesn’t like to toot his own horn, but he has a tremendous amount of expertise in TIG, MIG and Plasma Arc Welding and Cutting products– you can read the details over at Arc-Zone.com or read some of the About Joe Welder posts right here.

And, if you have a welding question you’d like answered, go ahead and Click on the Contact Joe link.

If your question is featured on an Ask Joe™ post, we’ll send you a t-shirt!