AC225 - Need Some Advice

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I'm building a hot rod in my garage and I have tacked the chassis together with my HD100 flux core welder.  I recently purchased an AC225 to finish welding the frame together.I was able to strike up and make ok beads with the 6013, 6011 and 7018's that came with the welder, but I need some advice on welding .120 square tubing, as my first attempts left me with Swish cheese.  I'm not used to the power of the 220V machine!I'm practicing by welding two 2x2x.120 mild steel tubes in a T. At first, I was using a 1/8" 7018AC at about 105 amps.  The arc blew through the edge of the open-ended tube.What would you guys use in this situation? A 3/32" 7018 at about 75 amps?  I was under the impression that my 110V machine was too small for this job and I needed some heavier amps to make the welds strong.  But I guess I can cool it down a bit for the .120.I did manage some nice strong welds on 3/16 using a 1/8 7018 at about 120 amps.
Reply:consentrait your heat on the closed tube and let it wash up onto the edge of the intersecting tube. too much heat on the edje will melt it away befor getting a good puddle on the othere tube. summer is here, plant a tree for mother earth. if you dont have time or space, sponcer some one else to plant one for you.feel free to shoot me a PM or e-mail me at [email][email protected] i got lots of time.
Reply:I see. So get the puddle going on the closed tube, then bring it up to the open one a bit quicker, then back down in a weave? I'll give it a try, thank you.
Reply:Yep, build up a bit of a puddle then pull it onto/into the end of the open tube.... it's a bit of a dance.
Reply:You probably want to drop the amps down a bit, maybe down in the 75-90 amp range like you alude to, and do what Fun and KRS say.  You might also go with a smaller electrode to fit the amps, but if you don't have a tight fitup, you may want to stick with the larger electrode to get more metal in the gap (I say "may" because I think this is below the suggested amps for 1/8" electrode in ac).  I have used this techinque, with a half moon weave "(((((", to span some pretty wide gaps  (maybe too wide).  As you approach the edge, the metal should be heated up enough for a nice even bead.  Fitup is really important here.  The tighter the fit, the less you will have this problem at edges.  Post a pic or two, let's see what you are up to.Last edited by smithboy; 09-25-2006 at 05:21 PM.Smithboy...if it ain't broke, you ain't tryin'.
Reply:I always found 6011's easier with an AC machine.
Reply:Thank you for your help guys.  I was able to make some decent welds using a 3/32" 7018 at 75 amps. I also tried concentrating the heat on the closed tube as you suggested. I used a 1/8" 6013 at 90 amps and made some good welds that way too.DIY turbo Z28http://JunkyardTurbos.com