1st picture is from the internet as a perfect weld. I was thinking the welds looked cold but I’ve got the machine cranked up way above the sheet metal setting.

 

Are you burning holes through the metal, maybe you are not holding the trigger long enough out of fear of blowing a hole. You said you were using an extension cord, try plugging your welder directly into the outlet and practice there to see if there is any difference..

 

My main problem is I can’t see. It maybe the HF helmet. Sort of all over the place burning holes, build up with no penetration etc.
Had too much crap to get plugged directly into the outlet but have done some serious house cleaning (at the shop) so now I can try a direct plug in.

 

Are we looking at the actual welding side or the opposite, kind of looks like the underside. Judging by your weld picture how clean the surrounding area is, I would say you are using the argon-co mix gas, are your gauges working and have proper flow. CO gas leaves a brown film and more splatter, flux core wire leave a lot more splatter and a blacker weld. I prefer the 75% argon-25% co mix really makes a difference in the weld. Find the first plug from the main panel and plug in there, and work there for trial welds. It looks to me like you have more than enough heat by the blueing on the right side, that heat coloration normally stays with in a 1/2 inch of the weld when all is right. I think you need to work on the wire speed. Set the heat range at the specified sheet metal setting and while you weld have someone turn the wire speed slowly up until you get the sound of frying bacon. If that heat range does not work go up one setting and repeat. After going thru all settings and still no success than you are going to have to figure it is either your power source or the actual welder. The other issue I am hearing is the part about not seeing the weld, seeing the weld is crucial as to being able to control the weld puddle which is created by heat, wire speed and your hand. Need to resolve this before any viable conclusion can be made on the unit. When I am running a good bead I can actually see the wire melting into the puddle

 

Thanks for the help gerrymoe. Too bad you’re so far away. We could probably fix my issues in hours not days.

 

I just had a thought this morning concerning your problem too. I was wondering if the polarity is connected properly for welding with gas or set up for flux core

 

You may be on to something John. What’s correct polarity for gas.

 

It should show a diagram under the hood, I'd have to go out and check mine before I could say for sure but depending what kind of wire you are using polarity needs to be reversed..

 

Are you getting the area to be welded down to good clean shiny metal ? Mig welders hate rust and simply will not weld properly reguardless of setting .

 

John you might have figured this out.BJ if you are using gas (co or Argon co mix) your polarity settings should be. positive to work gun. negative to ground clamp, using flux core wire it is negative to gun positive to ground clamp. Your installation manual should explain this . Really hope this is it because it will be an easy fix for ya

 

Ebear, I wire wheel and then do a light grind on the area. But it’s impossible to get to the back of the patches in some cases.
Gerrymoe, unfortunately I’m pretty sure mine is set up positive to the gun negative to the ground. I’m taking a short vacation in Florida this week so it’ll be next week before I can check.

 

BJ

The suspense will be tough but I wish you and family a relaxing, worry free vacation.

 

Got my chassis back from the exhaust shop today. Those Smithys sound nice.

 

Still no Cab for the frame. But there is some progress. I ordered a complete bed (less fenders) and it has been delivered. Yesterday it almost got to 70°F but I had a long list of Honey Dews so no Truck time. But today. Ever since I got the frame back from the exhaust shop the engine was running rough. Since everything is new (just rebuilt the engine two years ago) I decided to start from scratch and retune it. Started by pulling all the plugs and readjusting the valves, nothing big but I did adjust a few. Just an FYI you can’t remove #8 spark plug without removing one of the power steering hoses off of the steering gear! Then I checked the plugs and gaps. Plugs were all carboned slightly (probably due to not being run on the road). Checked gaps a couple were a little too much so reset them all. Then I rechecked wires #6 & #7 were reversed. Corrected that issue and all is well. Purring like a kitten now. If I only had a cab.

 

Glad you had a 70 degree day. Looked like on radar you might have got some rain too. We go slammed with a blizzard today. About 4" of snow with 40-50 mph winds Could have been worse! 12" - 15" in central NE. Anyway, glad you figured out the rough idle. I watched your Dec. 11th post and the engine sounds great. Any idea on your cab? Hope to get mine back within a couple months and then chug forward. The race is on