Flux core Q's and I brought pics

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First off.  Lincoln Pro Mig 175 wire feed, .035 Innershield wire, 3/16" mild steelAlrighty.  I got the process down pretty good.  I can make the weld look good and it holds, but when I cut apart the pieces I'm welding there is an ever so small area that appears to not have been penetrated.  I know that eventually my weld will fail from this lack of penetration.  And I am practicing for welding a c-notch into my truck frame, so this puppy has got to hold.I've been told I need more heat.  So I turned the dial from D to E to increase voltage and then did some test beads to get the wire speed right.  Now I'm literally cutting into the material I'm welding.So my question.  Can I just run the first bead on the E voltage, clean the welds very good and then run 2 subsequent passes on the D level?  Or am I staying in one place too long and is that inducing the burn in.  I think it's called undercutting.Here are some pics from the not fully penetrated pieces:  Forgive me if I post the pictures incorrectly.  I'm just uploading them from my Photobucket.  The larger bubbled weld should be disregarded...I did not clean the previous weld and was just laying some beads down to get the process down.  I know it's an ugly weld hiding a weld. The pictures are from D voltage, wire speed set accordingly.So what should I do to correct this?  And please dont say, "Get gas."  Believe me, I know.  Trust me I would if I could but I can't swing the cylinder price right now.  It will come eventually.  And the machine says it will weld I believe 1/8" with MIG, but thicker with flux core, so I'm using the flux core for my frame notch.  Anybody have a max weld with this machine either? Attached ImagesLast edited by bignick31985; 04-08-2007 at 07:52 PM.
Reply:That's a 230V machine, right?  You can do 1/4" in GMAW easily.  But, still FCAW is a great process for this.  I like your idea to turn it down a notch for the other passes.  Clean all slag before the next pass.You are using an E71T-11 wire, right?  Some FCAW is not rated for multipass.
Reply:From what I see..Looks good..Just a little penetration issue in the deep corners..There is a little "tunnel" between the piece and the weld..But not bad..Next time try a little bevel..root pass then cover pass... ...zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Zapstar,.... Are you a Bracket racer with you car or maybe Super Street/Gas and is that a Div 1 number on the window or IHRA?  I know it's not welding per se but I've got one of those toys as well.
Reply:Yep, a 220v machine it is.  Good to know I can go that thick with MIG when I decide to get the bottle and all.  I have the regulators and hoses, just no bottle. Wire is 211-Innershield .035 wire.  Not sure if it fits the name of the wire you typed though.I'll try a little more bevel, then secondary and tershiary passes at a lower heat setting.  Unfortunately I'm out of metal...have to hit the Lowes tomorrow I guess.Thanks for input fellas.  I'll give it a shot and repost the success (hopefully, lol).
Reply:Yes, Lincoln's MP-211 Innershield is an AWS E71T-11.  You're okay for multipass.You're buying your metal from Lowe's???  If you're that rich, let me give you my address.  Donations to me are tax deductible!Ironically, though, Home Depot has the best price I've ever seen on that Lincoln Innershield.
Reply:I run .035 flux core in a 175 machine quite a bit. If you are wanting 100% penetration or near that on 3/16ths without allowance for fillet size then your going to have to bevel. No way around it. Bevel on both sides or leave a gap, and gaps are pretty difficult to maintain even with planning and forethought. I'm running some NR 211 right now and it can be a bit ornery to dial in. Nice wire just finicky. If you are familiar with your machine it's no biggy, but if not it can be problematic. For what you are doing you do need to stick with something rated for multi-pass tho.
Reply:Yes, more heat into the corner.  Try a triangle weave.  One side, CENTER then the other side.  Start again at original side, CENTER....... Point that wire right into the corner with the far edge of the wire hitting the bottom edge of the verticle plate.  Keep the first bead small.  The center of the bead will be out in front a little.  If you do a back and forth weave, don't forget the wire is further away from the corner which changes your stick out and welding voltage.  This makes for more fill and less dig.   NR-211MP.  The MP stands for multiple pass.  Try a little less stick out on the first pass.Have FunDavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:You answered your own question...Get gas..LOL