So I set my Readywelder up to see what I could do with some theories.
First up. I succesfully added a microswitch inside the readywelder to act as a contactor controller. This allows the Readywelder trigger to activate the main contactor in my Betamig 250.
It was rather tricky getting the microswitch positioned inside, and I don't really know how long it will last, but what the hey, ya gotta try.
I ran the wires from the switch to a panel mount 1/8" Audio jack that I mounted down by the wire spool. This allows me to simply plug in a wire set that goes to the contactor control connectors in my Betamig 250.
This way the Readywelder will act just like a real spoolgun.
Basic setup. Miller Maxstar 200DX inverter set to Stick mode. Running from a 110 volt outlet.
30 CFH C25 gas. Readywelder 10250
The next bit was to try to weld 16 ga steel using 0.023" steel wire. As suggested by a wise soul, the Dig control was the key. With the Dig control set to 100% on my Maxstar, I was able to put down some lovely beads on 16 ga sheet, and even some nice fillet welds on 1" x 1" x 18 ga steel tube.
With the DIG control set to 0 it was hopeless to get anything useful on thingauge steel. The Dig control increases the output amperage at a lower open circuit voltage for stick welding with certain electrodes, like 7018, so uphill and overhead are easier, with less sticking. For agressive rods like 6010 or 6011, Dig control is reduced, since these rods prefer a higher open circuit voltage.
So some settings to play with.
16 ga steel, 0.023" wire, 60 amps, 3.5 wire speed, Dig 100%.
1/8" steel, 0.023" wire, 100 amps, 6.0 wire speed, Dig 100%.
1/4" steel , 0.035" wire, 130 amps, 1.5 wire speed, Dig 50%.
The only modifications I have made to the gun were to add a 1/4": o-ring under the dial to stop it from free-spinning, and I high-lighted the speed marks with a white paint marker, and added half way marks between the dots.
BTW At first I was having terrible feed problems on the 0.023" wire. I just could not get the gun to feed the 0.023" wire strong enough to overcome the spool friction, even with the wire feed roller tension set to max tension. Then I got smart and drilled out the hole in the wire spool to 21/32". The wire fed perfectly after that, so if the wire spool seems too tight try drilling it out a little bigger to reduce friction.