An electrode alignment device and weld head for automated welding machines includes a base member, a gap wheel, an electrode holder and a coupling rod. The gap wheel includes a plurality of graduations, where each graduation corresponds to a predetermined electrode spacing for an automated welding process. In one embodiment, the graduations in the gap wheel comprise pairs of apertures, with a first aperture for engaging an alignment post on the base member, and a second aperture for engaging an alignment post on the electrode holder. Among the graduations, the spacing between the first and second apertures is different. As such, the electrode spacing may easily and accurately be changed by disengaging the coupling rod, rotating the gap wheel to the proper graduation, and reengaging the coupling rod.