Help Blowing holes in 16 gauge

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I have been out of practice awhile but man I'm ready to scream. Am I the only one who blows holes in 1"x1" steel tubing (16 gauge). I tried my miller 180 mig with auto set and manual either way I seem to burn a hole. Half the weld look really good 1/4 are ok and 1/4 have holes which I  hate.
Reply:Concentrate on keeping the wire pointed right into the joint.  Don't wander off to one side or the other.  Watch the puddle.  Take time cutting your pieces so they fit up nice.  If it's too hot, turn it down.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:ThanksMy fit up is good. By wandering do you mean zig zag? I tend to do this (note self taught). Should I just go straight forward or drag the gun with no side to side motion?Thicker metal seems so much more forgiving.
Reply:what are your settings right now? i would start in the 16v range with .035 wire and adjust the wfs from there. Is there opportunity to tip the weldment so that you can run it vertical down?
Reply:Yes I could run it vertical down. My machine is set on "3" not sure what the volts are.
Reply:First, are you using fluxcore or solid wire and gas?If fluxcore, just drag it straight back, forget the weaving for now.If solid wire and gas, push it forward straight along, forget the weaving for now.By wandering, I mean wandering.  Don't get off to the side of the joint with the wire.  Point it right at the center of the joint and move it in a straight line.If you're having trouble seeing the joint, shine a shop light on the work area, or use a lighter shade lens, or wear eye glasses.If you're using fluxcore wire, dont let the stickout length get too short.  The shorter the stickout, the hotter the arc.   Concentrate on maintaining a consistent stickout length as you move the torch along.Hold the torch so it is straight up and down to the workpiece (side to side, not forward and back).  Don't lay the torch over to one side.  If you keep it at 90 degrees to both sides of the joint, then both sides will get equal heat.  Wherever you point that wire, that's where the heat will go, so point it right down at the joint.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:Thanks DesertRider33. I'm going to bed and attack it in the morning. I wish you lived near here so I could watch you weld.
Reply:I am presently building my cart for my mm 180 and using same steel,my settings with 100% co2, .030 are 3/30 or a little above which is pretty much the chart value.I found that doing a circular motion helped, it at least prevents the wire staying on an edge too long and blowing out the edge and causing a hole esp if there is a gap.
Reply:I forgot I'm using solid wire with gas.
Reply:What size wire? .023-.024 will be more forgiving than .030 on thin stuff with that machine. Many times the reason you blow holes is you are moving way too slow trying to build up a bead. Might want to try a faster progression.QamuIs Heg qaq law' lorvIs yInqaq puS
Reply:I've welded some 16 gauge 1x1 tubing with my HH 175.  I've found I need to turn the voltage down & adjust the "heat" with the wirespeed.  Higher number on the wirespeed = more amps = more heat, lower number on the wirespeed = less amps= cooler.  I've found the the chart is a good reference on my Hobart, but I ignore it on the Lincoln.  Adjust your numbers a bit cooler to prevent the burnthrough.Try dropping your tapped number to 2, keep the wirespeed the same.  Be ready to move once you strike an arc.  DeserRider is correct with .030 wire & thin metal.  Point directly at the joint, push it away from you.  Keep your angle equal from the vertical/horizontal surfaces.Pics would help once your done.MarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:Originally Posted by ReebsThanks DesertRider33. I'm going to bed and attack it in the morning. I wish you lived near here so I could watch you weld.
Reply:Thanks again I will be back at it in a few hours. I might get some lighter wire. But first "chores".
Reply:I was trying to learn to buttweld two pieces of 16ga 3" tube together and I was having trouble getting good penetration without burning through. Setting the machine on 2/20 I was either moving too fast and not getting enough penetration or moving too slow and burning through. I was finally able to et a couple good welds but was still not happy. Then a buddy gave me some tips and I had upped the voltage to 5 and wire speed to 50. Using the "tack tack" method (a series of quick, overlapping tacks around the joint) I was able to get a complete weld
Reply:I only use the tack, tack method on very rare occasion, like if I have a really bad fit-up on somethin thin and unimportant that can't be welded in one continuous bead.  Tack, tack is a bad practice to get into, you should avoid it if at all possible.   It's ok on something thin that isn't of any strength importance, but don't use it on anything you actually want to hold together under any kind of stress.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:OK life is good!I got some .024 wire and that made a big difference. I tried your idea of straight bead in the joint that helped also. Plus i did not realize my location info was not posted. Thanks dabar39. Once I charge the batteries on the camera I will post some pictures (not of the holes). Be gentle. In all seriousness is 16 gauge harder for some people or is it just me?Dave ReberWadsworth Ohio
Reply:Thin stuff is hard for me too.  I don't have any small wire, so I'm stuck with .030 wire solid & flux core.  I do have a small roll of .035 flux core, but don't like how it runs, so I rarely use it.MarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:They sell small wire at the weld supply... But really, you don't need any smaller than .030, solid or fluxcore, to weld 16 ga tube.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:I seem to get some pretty nice welds with good penetration using the tack tack method on thin tube. I can run a straight bead but I end up having to stop to turn the piece I am welding anyway
Reply:I can order it too.  I just don't do enough thin stuff to worry about it right now.  The .030 works just fine for me.  I love the sound the solid wire makes after about a second of welding............nothing but hissssssssss.MarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:Originally Posted by DDA52What size wire? .023-.024 will be more forgiving than .030 on thin stuff with that machine. Many times the reason you blow holes is you are moving way too slow trying to build up a bead. Might want to try a faster progression.
Reply:farmersamm once Trick or treating was over I ran to home depot and got some .024 wire and started practice beads on scrap. I think move move move is the key.Dave ReberWadsworth Ohio
Reply:Originally Posted by 874crawlerI seem to get some pretty nice welds with good penetration using the tack tack method on thin tube. I can run a straight bead but I end up having to stop to turn the piece I am welding anyway