0469837881 - ESAB Aluminum Wire Outlet Guide .035-1/16

Stop Bird-Nesting and Keep Welding

If you have ever tried to push soft aluminum wire through a MIG feeder set up for steel, you know the headache of bird-nesting. The wire kinks, tangles, and stops feeding right when you are in the middle of a bead. The ESAB Outlet Guide 035-062 Soft (0469837881) is the solution to that problem. This little part plays a huge role in keeping your day running smoothly. It is the specific guide tube designed to sit right after your drive rolls and funnel that soft, flimsy aluminum wire straight into your gun liner without letting it wander or buckle.

This guide is sized perfectly for wires ranging from 0.035" up to 1/16" (0.062"). Unlike steel guides which might be too hard or have sharp edges that shave off tiny flakes of aluminum, this "Soft" guide is made to be gentle on the wire. Those shavings are the enemy—they clog up your liner and contact tip, causing burn-backs and erratic feeding. By using the correct guide, you reduce friction and keep the wire round and clean as it enters the cable. It is a small upgrade that makes a massive difference in how your machine handles 4043 or 5356 alloys.

Swapping out your outlet guide is a quick job that should be part of every wire changeover. If you are switching your ESAB feeder from running hard wire to aluminum, do not just change the rolls and liner—change the guides too. This part (0469837881) drops right into place on compatible ESAB feeders. It aligns perfectly with U-groove drive rolls to create a fully supported path for the wire. No gaps means no place for the wire to escape and tangle.

Don't let a cheap or wrong-sized guide ruin your welds or waste your expensive aluminum wire. Keep a few of these ESAB Outlet Guides in your toolbox. When the wire feeds smooth, the puddle flows smooth, and you get the stack-of-dimes look you are aiming for without the frustration of stopping to clear a jam at the feeder. Trust genuine ESAB parts to keep your rig welding like it should.