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Hi Ryan, Like stated, check your drive rolls for the proper wire size (stamped on the side of the drive rolls) as well as make sure the drive rolls are burr free. Having to install new drive rolls is not uncommon when using AL wire as steel wire will leave a burr on the roll. Some teflon liners will work with Alumnimum on short length whips (under 10ft) but from past experience I would suggest a spool gun as there's less headaches with students just learning to weld AL. Set the drive roll tennsion very loose then tighten "just" enough to push the wire with a small amount of wire resistance between your fingers then Run a couple feet of wire out then run your fingers across the wire feeling for any wire flatness or roll teeth marks confirming too much roll tennsion. I also like to use a tip cleaner and open the tip about .001 larger than stock diameter as this helps keep the wire from balling on the drive rolls. Use a foam ear plug on the wire before the first drive roll as this helps to keep the wire and liner clean. Trim wire to a sharp point then push thru the foam letting the large end of the foam rest against the drive roll. T_Bone
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