Bernard® BTB Gun Transforms Aluminum Welding for 4-Star Trailers

For the past 40 years, 4-Star Trailers in Oklahoma has built high-quality aluminum stock and horse trailers. Aluminum is lightweight, corrosion-resistant, and strong—ideal for trailers designed to endure tough road conditions. However, welding aluminum with a push-pull gun has its challenges. The heaviness of the tool can make it difficult to maneuver in tight angles, and the added weight can lead to welder fatigue, especially when working on large parts or frames. Additionally, this setup can cause delays in production timelines due to discomfort and inefficiency during long hours of use.

Before switching to the Bernard® BTB Semi-Automatic Air-Cooled MIG Gun, the team regularly faced feeding issues. The feeding problems were especially noticeable when working on large aluminum parts, causing disruptions and affecting their ability to keep up with demanding production schedules. The difficulty in maneuvering the push-pull gun, coupled with the physical strain it placed on welders, contributed to frequent delays and a slower pace of work.

The BTB Gun has been a game-changer. It pushes aluminum wire long distances with ease, something that wasn’t possible with the previous system. Its design is lightweight and maneuverable, making it far easier for welders to handle, especially in tight spots. This has significantly reduced fatigue, allowing the team to work longer and more comfortably without sacrificing quality. The customizable neck lengths of the BTB Gun are another huge advantage, allowing welders to reach into tight angles or handle bigger components with greater ease.

The Easy Feed Liner in the BTB Gun reduces friction, making it simpler to feed aluminum wire and minimizing downtime—critical for maintaining a steady workflow in a busy shop. With fewer interruptions, the team is able to stick to production goals and meet deadlines more effectively. The use of AccuLock consumables also contributes to less maintenance, as they last longer than other options, cutting down on the frequency of replacements and the time spent on maintenance tasks.

The biggest benefit? The team is more productive and satisfied with their work. With fewer interruptions and smoother operations, they’re able to produce high-quality welds faster. The BTB Gun has not only made their jobs easier but also helped the business run more efficiently. It’s become an indispensable tool in their shop, enabling them to build even tougher, more dependable trailers while improving overall productivity and welder satisfaction.