268848 - Miller XR Series .040 Aluminum Polished Drive Roll Kit

Smooth Aluminum Feeding with Miller 268848

If you have ever struggled with aluminum wire bird-nesting or shaving inside your feeder, you know that having the right drive rolls is half the battle. The Miller 268848 Drive Roll Kit is the solution for welders running .040" aluminum wire through Miller XR series push-pull guns. Aluminum is notoriously difficult to feed; it's soft, it bends easily, and it hates friction. This kit is specifically designed to handle those challenges, ensuring your day is spent welding rather than clearing jams from your gun liner.

The secret to this drive roll's performance is its "polished" design. Unlike knurled rolls that grip steel wire with teeth, these rolls feature a smooth, polished U-groove. This shape gently grips the aluminum wire, pushing it forward without biting into the surface. This prevents the creation of aluminum shavings—tiny metal flakes that can accumulate in your liner and contact tip, causing micro-arcing and erratic feeding. By keeping the wire round and smooth, the Miller 268848 ensures excellent conductivity at the tip and a stable, consistent arc on your workpiece.

This kit is a direct replacement for the older part number 196301, so if you are maintaining an older XR system, this is the modern upgrade you need. Installing the correct drive rolls is one of the cheapest and most effective ways to improve your weld quality. When your wire feeds smoothly, your travel speed stays consistent, your bead profile looks better, and you reduce the risk of burn-backs. It is designed specifically for the .040" diameter, so you get a perfect fit every time.

Don't let poor feeding equipment hold back your aluminum projects. The Miller 268848 kit gives your XR feeder the grip it needs without the damage you hate. Whether you are fabricating aluminum boat hulls, truck boxes, or custom signage, relying on genuine Miller drive rolls means you can trust your equipment to perform. Keep a spare kit in your toolbox to ensure you are always ready to tackle aluminum jobs with confidence and precision.