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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 Icon 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.

Install wire spool
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
Dials: 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 or 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
Half Inch 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 Button