distance is more by feel, but should not be more than 1/4" away from the weld. Angle is debatable, generally it should slightly point in the direction you are going. This is not an absolute, but generally true. You have to play with the wire feed to find your best running setting, everyone is different. The distance is generally such that you can see what you are doing, but not to the point the weld spatters excessively. It's all by feel and experience, the more you do, the more you get comfortable. Turn up the gas flow though, as it doesn't take much to blow the sheilding away. WIth the fill being that low, it also was a contributing factor. As for the cosmetics, with powder coat, no filler will work, it has to be clean metal, so you will either have to reweld or sand and buff, the reweld would be hard to hide, so sand and buff would be the best option.

 

The porosity you describe, (near the surface, tiny round bubbles) sounds like a classic case of shielding problems. Wind is a big culprit, but the bottle being near empty may be as well. The condition of the gun/nozzle is important, as I've seen guns leak gas out the back side of the nozzle or inside the handle. The first reaction is to turn the gas up higher, but this sometimes makes the problem worse. Open your drive roll so it pushes no wire and pull the trigger. With the gas set low (20 or less) feel and listen to see if it's all coming out the end of the nozzle. Also check where the wire goes into the gun at the drive roll end and see if you're losing it there. You can also put a thumb over the end of the nozzle and see if you have leaks. Doing this will force a little out the back side, or at the machine end, but it shouldn't be much. You want minimal leaks. Shielding does have to be adjusted for the circumstances, but it's one area where more isn't always better. You just want it to shield adequately, but any more than that is wasted, and it isn't that cheap. As far as angle, I use about 60 degrees. Just enough to see the wire and puddle, but straight enough to keep the gas blowing straight onto the puddle. Also, while I've seen people make decent looking welds dragging the gun, the correct way is to push it forward as you go. The only time i move 'backward' is on a vertical-down weld.

 

What 200000 said. What you describe sounds like sheilding problems. Weld is prolly fine for what you are doing. All these guys are right on. The difference in the prescriptions is every one of us has a different set difficulties we deal with every day, so we tend to try to cure those first. Good advice from all.

 

get some soapy water and check all your connections for gas leaks . thats the first thing I'd do. If thats good make sure your welding hot enough

 

Highboy 74, I have run into the same problem. I've found that when the bottle pressure falls below 100 psi, it isnt a reliable reading. I had been doing some welding on a trailer frame and got some porosity in the weld. I had 75 psi in the bottle, but when I checked my flow regulater the ball was only showing about 7psi.
When I weld mig, I angle the nozzle back about 10 to 20 degrees and travel in the same direction as I am welding. Your welding wire tips should be recessed into your nozzle about 1/4 of an inch. I normally run my nozzle about 1/4 or so above my pool. If your welding outside, and there is a little brezze, build a cardboard barrier to try and block the wind. I've had to do that many times. Well thats my two cents worth, I hope it helps.