Forney 242 Dual MIG Welder Quick Start Guide

Posted by Katelyn Crocker on Jun 21, 2018 11:03:34 AM

In Forney Industries, MIG welding

Stock Image of Forney 242 Dual MIG Welder

Get started with the Forney 242 Dual MIG Welder! This is a breakdown of the Quick Start Guide that is included with your new machine.


1. Read User Manual

2. Assemble front handle, trim pieces and wheels. (Tools needed: screwdriver and snap ring pliers)

 Assembling front handle Assembling trim pieces

3. Attach gas bottles and regulator hose(s) assembly. (Tool needed: adjustable wrench)

Attaching gas bottle Attaching regulator hose

4. Install wire spool. Insert wire through both wire liners and clamp it into wire drive. Make sure drive roll, liner and tip are correct for wire diameter.

Inserting wire through both wire liners and clamp it into wire drive Correct installation of wire spool

5. Install MIG gun, turn it on, and squeeze trigger until wire comes out.

Replacing consumables after wire comes out  Plugging in MIG gun

6. Tighten wire feed tension knob clockwise until wire will bend from feed tension at 2”-3”. Verify polarity is set correctly for MIG or flux-core welding wire.

Adjusting tension knob  Verify polarity 

7. Adjust wire feed speed and voltage per chart on the inside of welder.

Wire Feed Speed knob on right  Voltage knob

8. Dual MIG setup

  • #1 - Standard MIG

  • #2 - Spool Gun
    1: Standard MIG; 2: Spool Gun

  • Verify gas, switch position and output (Note: Wire feed speed is adjusted on the spool gun).
    Verify your gas, switch position and output

Weld Examples

Good Weld

  • Smooth bead
  • Minimal spatter
  • Good fusion
    Good weld


  • Too wide
  • Bead too flat
    Current/WFS too high

Current Too Low

  • Lack of fusion
    Current too low

Weld Speed Too Fast

  • Stringy and lack of fusion
    Weld speed too fast

Weld Speed Too Slow

  • Melt through
    Weld speed too slow

Stick Out Too Long

  • Excessive spatter
    Stick out too long

Welding Tips

Optimal Stick Out

  • Stick out 1/2” +/- 1/8”
  • Short stick out = more current and more penetration
    1/2" stick out


  • Affects the arc shape
  • Less voltage = tighter arc and potentially more spatter

Wire Feed Speed (WFS)

  • Higher wire feed speed = more amperage
  • Can also affect arc shape and penetration
    Wire Feed Speed Knob

Travel Speed

  • Affects bead width and height
  • Can also affect penetration
    Travel Speed

Thin Material

  • Less voltage
  • Lower wire feed speed
  • Faster travel speed

Thick Material

  • More voltage
  • Higher wire feed speed
  • Slower travel speed

Forney 242 Dual MIG

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