DIY Welding Project: Building a MIG Gun Handle Hanger | MillerWelds

DIY Welding Project: Building a MIG Gun Handle Hanger

In this step-by-step tutorial for beginner welders, Andy demonstrates custom welding techniques for creating round and flat hook styles for your MIG gun handle hanger.

Download Project Plan

SKILL LEVEL: Beginner

TIME COMMITMENT: 2 hours

Here's what you'll need to get started.

Tools and Materials

Miller® Multimatic® 220 AC/DC multiprocess welder

3/32" size 5356 Hobart® filler metal

Bandsaw/cutoff wheel

Vise grips/clamps

Grinder/sander

Hammer

Bench vise

1/4" aluminum round stock (for round hook style only)

1" x 1" aluminum angle, 1/16" or 1/8" thickness

WARNING: READ AND FOLLOW ALL LABELS AND THE OWNER'S MANUAL.

Step by Step (Round Hook Hanger)

STEP ONE:

Begin by cutting a piece of the 1-inch x 1-inch angle to a length of 1-5/8 inches. Ensure your cuts are precise for a proper fit.

STEP TWO:

Next, mark 7/16-inch from the inside edge of the angle. This will be your guide for the next cut.

STEP THREE:

Carefully cut along the edge of the line so that the saved part maintains a width of 7/16-inch. Take your time to ensure accuracy.

STEP FOUR:

Deburr the cut edges to remove any sharpness and ensure a smooth finish.

STEP FIVE:

On the short side of the angle, mark for holes that are 1-1/8 inches apart, 3/16-inch from the top edge and 1/4-inch from either side. These marks will guide your drilling.

STEP SIX:

Use a center punch to create indentations at the marked points, then drill the holes using a #26 or 9/64" drill bit.

STEP SEVEN:

Cut a 3-5/8-inch piece of the 1/4-inch round stock. Ensure the cut is clean and straight.

STEP EIGHT:

Form a radius on one end of the round stock. This will help in creating a smooth hook shape.

STEP NINE:

Find a 3/4-inch round piece of tubing or a bolt to use as a form for bending the hook. This will help achieve a consistent curve.

STEP TEN:

Hammer form the 1/4-inch tubing around the tubing. Start about 2-1/4 inches from the rounded end to create the desired hook shape.

STEP ELEVEN:

Cut two pieces of the 6 mm OD x 4 mm ID x 20 mm long standoff spacers to a length of 7 mm or .275 inches. Ensure the cuts are precise.

STEP TWELVE:

Remove the top two cap screws from the gun handle. Temporarily install the spacers and the mounting bracket using two 6-32 x 7/8-inch-long socket head cap screws.

STEP THIRTEEN:

Determine where you want your hook welded. I centered mine on the gooseneck for balance.

STEP FOURTEEN:

Remove the mount from the gun and grind a small flat spot on the bottom of the hook where it will mate to the gun mount. Clamp the hook in place and weld it securely.