Abstract: Several aspects of an in-line welding gun are disclosed. In one aspect, the welding gun has a variable profile insulating boot disposed over the torch barrel of the gun. The variable profile insulating boot may be comprised of a molded material having varying thickness to provide the desired insulating properties. In another aspect of the welding gun, a speed control mechanism for the motor driving the wire feed assembly is positioned in a recess in the housing such that it reduces the risk of being unintentionally adjusted during operation of the welding gun. In another aspect of the welding gun, the wire feed mechanism features a feeder roller and an idler roller that may be separated without opening the housing of the welding gun. To separate the rollers, the user may depress a portion on the exterior of the housing to press on a pivotable lever on which the idler roller is disposed.

Abstract: According to one embodiment of the invention, a contact tip for a welding gun comprises an elongate body having a first end, a second end, and a first opening extending longitudinally between the first end and the second end. The elongate body has an outer surface and an inner surface. The elongate body has a second opening extending radially through a side portion of the elongate body between the outer surface and the inner surface. At least a portion of the second opening is configured to support a contact element. A contact element is configured to be supported within at least a portion of the second opening of the elongate body and extend at least partially into the first opening of the elongate body. A retention member is configured to couple the contact element with the elongate body.

Abstract: A welding gun includes a motor, a wire feed mechanism, a power block, a welding tip, a and a cup. A substantially rigid shell surrounds the motor to form a handle. A gas passage for receiving inert gas from an inert gas source and delivering the inert gas to the gas path in the torch barrel extends at least partially within the handle.

Abstract: A welding gun includes a motor, a wire feed mechanism, a power block, a welding tip, a and a cup. A substantially rigid shell surrounds the motor to form a handle. The gun includes a spindle, a spool and a quick disconnect mechanism for coupling the spool to the spindle.