Thanks to all of you that have replied !! I really appreciate your input !! I'll try to address each one: To Steve... Yes, I could take a hammer and smash the nozzle, but I have a sneaky feeling that won't help (other than just getting frustrations out ). To Oddjob83... Your thoughts are close to mi...

Oh... And to help clarify...
I can run spools of 5356 all day long and not have this issue.

Thank you for your reply, Steve. As best as I can tell, the gun is a Miller SpoolMatic. Concerning the drag on the spool: The wire is coming off the spool well. The wire is bird-nesting between the pull roller and the liner, which tells me something with the liner and/or tip is causing the issue. If...

Greetings, All ! I have been having constant problems with a Miller spool gun running 4043 .030 wire. The problem is that about half way through the spool, the wire keeps bird-nesting between the pull roller and the liner leading into the nozzle. This happens with 3 different brands of wire, and doe...