[shipj0]

Just an idea I am using with success for burn back ruining contact tips. I purchased a #54 drill bit and re-drill the hole from the threaded side out. Most times the aluminum plug just pops out. Then I lightly file or SS brush the top clean. Don't know how many times it will work but have done 1 tip 3 times with success. I am running a .046 wire but the hardware store has bits that would accommodate .035 and .030 as well. The bits were in a drawer not on a bubble pack on the shelf and cost about $1.50 each. Pays for itself pretty quick.

[Diesel]

I've done that and used a quick hit on a flap wheel. Works pretty good and doeant seem to damage it. Same with flux core it i can break the wire free. Although this is one of the reasons I dislike mig. Constant crap like this.