408023-001 - Tweco .035 Aluminum Drive Roll Double U-Groove

Smooth Aluminum Feeding Starts Here

If you have ever struggled with aluminum MIG welding, you know the nightmare of "bird-nesting"—when the wire tangles up at the drive rolls instead of feeding through the liner. Often, this frustration stems from using the wrong type of drive roll. The Tweco 408023-001 Double U-Groove Drive Roll is the specific solution designed to fix this problem for welders running .035" (0.9mm) aluminum wire. Unlike the knurled rolls used for flux-core or the V-groove rolls used for solid steel, this U-groove roll is designed to treat soft aluminum with care.

Aluminum wire is soft and easily deformed. If you use a standard V-groove roll, the sharp edges of the V bite into the wire to get traction. On steel, this is fine. On aluminum, it squishes the wire into an oval shape and shaves off tiny flakes of metal. These flakes clog your liner, and the oval shape causes drag in the contact tip. The result? Erratic feeding, burn-backs, and the dreaded bird-nest. The Tweco U-Groove roll solves this by using a smooth, rounded channel that grips the wire by friction across a wider surface area, pushing it gently but firmly without changing its shape.

This drive roll features a "Double" configuration, meaning it has two matching grooves. When you eventually wear out one side after hundreds of hours of welding, you don't need to buy a new part immediately—just flip the roll over and you have a fresh groove ready to go. This adds significant value and keeps you welding longer. It is sized perfectly for .035" wire, which is ideal for welding thinner gauge aluminum sheet metal often found in automotive, marine, and repair applications.

Installing the correct drive roll is the first step in optimizing your aluminum MIG setup. Combine this roll with a Teflon or polymer liner and an oversized contact tip, and you will experience a dramatic improvement in arc stability and feed consistency. Don't let feeding issues ruin your welds; equip your Tweco or compatible feeder with the 408023-001 and experience the difference a purpose-built component makes.