The Chicago Electric Flux 125 Welder: An In-Depth Overview
The Chicago Electric Flux 125 welding machine is often highlighted as an affordable option suitable for hobbyists and beginners seeking to get started with welding projects. However, it’s essential to understand that this welder belongs to an earlier generation of traditional transformer-based models, which are now considered outdated compared to the more advanced inverter technology available today. While its low price point is appealing, it comes with limitations that could impact your welding experience and project outcomes.
This unit is a 125A flux-core welder that solely operates on AC power, weighs approximately 38 pounds, and is designed primarily for light-duty tasks. Its construction features a fully metal casing, which provides durability but also contributes to its hefty weight. The device’s design emphasizes simplicity, but it lacks many of the modern features found in contemporary welders, such as digital controls or multi-process capabilities. In this review, we will explore its specifications, advantages, drawbacks, and suggest a more suitable alternative for those seeking greater value and performance.
What’s Included with the Chicago Electric Flux 125
- Chicago Electric Flux 125 welder unit
- Built-in flux-core welding gun (6 feet)
- Ground clamp (6 feet)
- Spare contact tips
- Instruction manual
While package contents for budget welders tend to be minimal, the included leads are relatively short and non-replaceable, which could limit flexibility in your workspace. The 6-foot leads are somewhat restrictive, especially when working on larger projects. The built-in design of the leads further complicates replacement or upgrading, as it requires opening the machine and possessing adequate wiring skills. The provided ground clamp is notably substandard, with poor conductivity due to the absence of copper contacts, necessitating thorough cleaning of the workpiece for reliable grounding. The MIG gun itself is basic, matching the overall budget-oriented design, but the clamp’s limitations can affect weld quality and ease of use.
Technical Specifications
| Welder Type | Flux-Cored |
| Input Voltage | 120V |
| Output Current Type | AC |
| Technology | Transformer-based |
| Amperage Output | 60A – 125A |
| Duty Cycle | 20% at 90A |
| Wire Drive Roll | .030” / .035” V-Knurled Roller |
| Wire Feed Speed Range | Unspecified |
| Wire Spool Capacity | 2 lb spool |
| Weldable Materials | Mild Steel |
| Maximum Metal Thickness | Up to 3/16 in. |
| Open Circuit Voltage | 27V |
| Dimensions | 14-1/4 in. x 8-1/4 in. x 14-3/8 in. |
| Weight | 38 lbs. |
| Warranty | 90 Days |
| Weld Guru Rating | ★☆☆☆☆ |
| Price | Affordable at Harbor Freight |
Key Advantages and Disadvantages
Pros
- Provides a stable welding arc suitable for beginners
- Offers infinitely adjustable wire feed speed for better control
- Simple and straightforward to operate, ideal for learning basic welding techniques
- Constructed with a durable metal body for longevity
Cons
- Relatively heavy and bulky compared to modern inverter welders
- Limited to AC operation, missing out on DC capabilities
- Short, non-replaceable leads restrict movement and flexibility
- Poor-quality ground clamp can hinder electrical conductivity
- Low open circuit voltage limits penetration and bead quality
- Low duty cycle restricts continuous welding sessions
- No digital display or precise controls, making adjustments less intuitive
- Short warranty period, only 90 days, offers limited protection
Important Considerations Before Purchasing
Limited Duty Cycle
The Flux 125’s duty cycle allows for only 2 minutes of welding at 90A before requiring an 8-minute cool-down period. This limits the amount of continuous work you can perform, especially on larger projects. While sufficient for small tasks, it can be a hindrance when tackling longer welding runs or thicker materials. Many modern welders offer significantly higher duty cycles, enabling longer, more efficient welding sessions without frequent pauses. Therefore, if your projects demand extended welding, this unit’s low duty cycle could become a major drawback.
Ease of Use and Control
The lack of a digital interface means you must rely on the adjustable knob and a min/max switch to set your amperage, which can be imprecise and less user-friendly. This setup might be acceptable for casual hobbyists but can hinder skill development for serious learners. Digital displays provide real-time feedback, helping users understand how settings influence weld quality, making it easier to replicate successful welds and learn advanced techniques.
Weight and Portability
As a transformer-based machine, the 38-pound weight makes it less portable than inverter models, which can weigh as little as 14 pounds. While it’s possible to move and set up this welder in different locations, its substantial weight can be cumbersome, especially if you need to transport it regularly or work in tight spaces. Modern inverter welders are designed to be lightweight and portable, offering greater flexibility for mobile projects or outdoor work.
Design Flaws and Limitations
The integrated leads, which are non-replaceable, pose a challenge if damaged or if you prefer different cable lengths. The wire feed system’s placement beneath the top cover limits spool size options, restricting you to small 2 lb. spools. Larger spools, such as 10 lb., can be used but may cause feeding issues due to tight fit and lack of official support. Additionally, the all-metal casing, while durable, increases the risk of damage if the unit is dropped or mishandled during transportation.
Warranty and Support
With only a 90-day warranty, the Flux 125 provides minimal coverage, especially when compared to other budget welders that often include one-year or longer warranties. Extended warranty options are available for purchase from Harbor Freight, but they add to the overall cost. Considering the age of this model and its build quality, investing in a more modern, better-supported machine can be a smarter choice for long-term use.
Superior Alternative for Better Performance
Although the Chicago Electric Flux 125 serves as an entry-level welder, it’s outperformed by more modern inverter-based models that deliver higher efficiency, better controls, and lighter weight. Among these, the YesWelder 135A Gasless MIG Welder stands out as a highly recommended alternative, offering significantly improved features at a comparable price point.
Why Choose the YesWelder 135A?
- Supports multiple welding processes: flux-cored, TIG, and stick welding
- Employs inverter technology for lighter weight and higher efficiency
- Provides a digital display for precise control and easy adjustments
- Offers a longer duty cycle—up to 60% at 135A—facilitating longer continuous welds
- Includes side-mounted wire spool support for larger spools (up to 10 lbs.)
- Lower weight at approximately 14 lbs., enhancing portability
- Extended 1-year warranty for peace of mind
- Compatible with 16A circuits, reducing installation costs and restrictions
This model’s versatile features, improved duty cycle, and modern design make it a smarter investment for hobbyists and small-scale professionals alike. It also comes with a more comprehensive warranty and better support from the manufacturer, ensuring durability and reliability over time.
Final Verdict
The Chicago Electric Flux 125 is a basic flux-core welder that may still appeal to absolute beginners due to its low price and straightforward operation. However, its outdated transformer technology, limited duty cycle, weight, and design flaws make it less suitable for serious or long-term projects. For those willing to invest a little more, the YesWelder 135A offers a far superior experience, combining advanced inverter technology with better controls, portability, and warranty coverage. As a result, it provides excellent value and performance, making it the ideal choice for hobbyists looking to grow their welding skills without constantly battling equipment limitations.
If you have experience with the Chicago Electric Flux 125 or have found it suitable for your needs, please share your insights in the comments below.