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I've had an old ESAB Smashweld 180 for years, a hand-me-down from my uncle's old bicycle repair shop. I don't weld often and the torch ended up with a stuck wire - likely from running corroded wire through the hose and leaving it there. All-in-all the original ESAB torch had reached its limit, with scratches, kinks, and rubber that was literally dissolving. It was time for an upgrade! In this guide, I'll walk you through how I replaced the old torch with a Danish Migatronic euro-style torch, including the little adjustments I had to make along the way.

To start, loosen the hex (Allen) fastener at the wire motor and gently pull the hose out. Before doing so, cut the welding wire and tie it off at the spool to prevent it from unwinding and tangling - trust me, a loose spool is a headache you don't want. The hose should come free from the machine with little effort.

Tip: If the hose feels stuck, rotate it a little side to side to loosen it without damaging the parts.

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With the old torch out, it's time to fit the converter. Start by trimming the internal guide tube to the correct length - cutting too much will cause problems, so trim a little at a time. Tip: Use the bench grinder for chamfering the guide tube - it makes for a nicer fit.

I also had to trim a small portion of the plastic shield because it was hitting a cabinet protrusion and wouldn't sit flush. This step can feel a bit fiddly, but the end result looks much nicer!

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Next, drill holes in the welder's front panel and bolt the plastic shield in place. Be mindful of the internal layout to avoid drilling into any critical components. Take your time with alignment to ensure the shield sits flush and looks neat.

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Overall, I found this modification relatively easy, taking about 2 to 3 hours to complete. However, I was surprised by how much adjustment was needed, considering the kit was advertised as a direct fit.

And there you have it! My Smashweld 180 now runs like new with its upgraded Migatronic euro-style torch. If your old ESAB torch has seen better days, this upgrade is well worth the effort.