Miller synchrowave 250 rattling

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Hey guys, I have a miller 250 synchrowave 2003 vintage. While welding in ac I'm getting what sounds like a rattle. I believe it to be coming from the HF points. It can best be described as sounding like detonation in an engine. I've gapped the points. I'm welding 3003 .063 using 1/16 green tungsten. Amps set at 71. Also occasionally it seems that either I'm getting a surge of voltage or the arc is destabilizing and making the puddle widen out for a second. Dc works fine. Any ideas?
Reply:

Originally Posted by benchracer1

Hey guys, I have a miller 250 synchrowave 2003 vintage. While welding in ac I'm getting what sounds like a rattle. I believe it to be coming from the HF points. It can best be described as sounding like detonation in an engine. I've gapped the points. I'm welding 3003 .063 using 1/16 green tungsten. Amps set at 71. Also occasionally it seems that either I'm getting a surge of voltage or the arc is destabilizing and making the puddle widen out for a second. Dc works fine. Any ideas?
Reply:I think today I'll turn the hf to start instead of continuous where it is set now.
Reply:Actually I was just reading that hf should be continuous. I dont have anybody capable of holding the torch so I'll find a block of aluminum and make a bracket to hold torch and try to verify the location of rattling
Reply:

Originally Posted by benchracer1

I think today I'll turn the hf to start instead of continuous where it is set now.
Reply:Got it. I'll report back this evening. Thank  you
Reply:I took the points out and they were in tough shape. I took them to the flat on my diamond grind wheel and cleaned the up. Took care of all the problems. Also found the hf rheostat frozen and burned contacts. Cleaned up and reinstalled. I will order new components. Thanx guys