Bad Welds. What am I doing wrong?

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I have a Lincoln weldpak 175hd and yesterday I was trying to weld a homemade ballast for my tractor with the frame out of 3x3 angle iron. The iron was rusty but I ground the rust off and I was using .035 flux at settings E-2.5 at first based on the guide on the welder. I tried several settings in the D & E range and changing the wire speed but the welds looked horrible with holes. I can't figure out what I am doing wrong. It seemed to be spattering very bad also.
Reply:Do you have the polarity set correct for the wire you're using?  Fluxcore self-shield wires run DC Negative (torch on the negative stud, work cable on the positive, which the opposite of solid wire with gas and gas shielded fluxcore.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:The polarity is ok, that is the first thing I checked because I thought maybe I didn't change it back from the last time I used the .035 mig.
Reply:Well holes equals porosity which means contamination, after you ground did you clean the metal to remove any oil or grease that may have been on there?
Reply:What flux cored electrode are you using. Not all self shielded wires run on DECEN and some flux cored wires are used with gas.
Reply:I don't know of any small diameter self shield flux core wires that his small machine would be using that run anything other than DCEN.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:after you ground did you clean the metal to remove any oil or grease that may have been on there?
Reply:Are you using an extension cord?  I had the same thing happen the first time with fluxcore.  It drove me nuts.  Went from a standard duty extension cord to my 10 gauge and all was perfect after that.Rene
Reply:When you ground the rust off, what did you use to grind it?  A wire wheel will remove the rust but leave the mill scale behind.  A sandpaper flap wheel or abrasive grinding disc will take off the mill scale.  You want to remove the mill scale.You are dragging the torch, right, not pushing it?  With fluxcore, drag it, like stick welding.  Also, don't go too fast, let it fill.  Keep your torch angle more vertical than horizontal.  Laying it down too much can result in little pin holes (porosity).  Also, keep the wire in the puddle.  Whipping in and out of the puddle can cause inclusions and porosity.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:Are you using an extension cord? I had the same thing happen the first time with fluxcore. It drove me nuts. Went from a standard duty extension cord to my 10 gauge and all was perfect after that.
Reply:It sounds like maybe a combination of things causing my issues. The first one being I don't know what I am doing!This is your only issue because everyone gave you good advice that would have resolved your problems. If you would have stated that you didn't know what you were doing in the original post then people would have given you different guidence.
Reply:This is your only issue because everyone gave you good advice that would have resolved your problems. If you would have stated that you didn't know what you were doing in the original post then people would have given you different guidence.
Reply:If your drive tensioner is set too high, it's possible to crush or even slightly misshape the wire.If flux-core wire is misshapen along the seam line the inner flux will leak out along the inside of your liner.Even if it's only a small amount that leaks out, it can be enough to cause porosity.Try setting your tensioner as loose as possible, then tighten it slowly just until the drive roll grips the wire and leave it at that setting.CWI, CWE, CST for Miller, Lincoln, Thermadyne, Hypertherm & ESABMillermatic 350PLincoln Invertec 205 AC/DCVictor combo torchESAB PCM 1125
Reply:galaxie428,Even a perfect looking bead by someone is suspect if that person hasn't put in the time to learn what it takes to make a sound weld.  If you have a chance you should test your welds to see how much fusion your getting.  Mig will not weld through mill scale, and is known as a cold process.  Even though your welds have held up you should put some time into inproving your skills because the first indicator of a quality weld is appearence.
Reply:Another tip, If you have insufficient wirespeed you will also get porosity,Nothing Ever Got Done By Quitting, Never Give Up.
Reply:Also make sure you grind a clean spot for your work lead...MillerMatic 252, HTP 221 w/cooler, Hypertherm PM45, Lincoln IdealArc 250 AC/DC"I'd like to believe as many true things and as few false things as possible"