welding my exhaust???

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i picked up a harbor freight mig 100 to weld my new exhaust on my car and im having the toughest time trying to get a good weld. its a flux cored welder and im using the supplied .035 wire. ive messed around with the wire speed and the heat settings in which it only has min and max. my best results so far have been with the wire speed on 8 and min.can anyone suggest any tips to help me out. my welds are very inconsistent and very ugly. ill get an "ok" weld for about an inch and then it all goes to hell. what am i doing wrong?
Reply:First thing I would do is get rid of the fluxcore wire that you have in there from Harbor Freight and get some Lincoln Innershield in there. After reading some threads in the HF Forum a few people said that the HF wire was nothing but junk and after switching wire, the welds looked consistantly better.Whats your wire stickout length? Usually 3/8 with fluxcore should be sufficient, but none the less your listening for a frying bacon sound.I can also imagine that most of your welding is out of position or under the car. I really dont know how to help you with that except wish you luck.
Reply:thanks ill try your suggestions.
Reply:Exhaust pipe can be tough to do.  Since your are getting a good bead sometimes, then it sounds like you need do make adjustment while welding.  Adjustment you can make: pull the gun back a little while welding this will minimally reduce the amperage,  move faster,  Anticipate burn through and stop weld allowing the metal to cool (seconds) then start again.  Maker sure fit up is good.  You do not need a gap.  Might want to do a series of tacks then connect the tacks.  Do as much off the vehicle as possible.  Might want to clear the galvanizing also.    With that tapped welder there isn't a whole lot of other adjusting to be done on the machine.
Reply:if your going with a new exausta flux core machine is not a good choice for thin wall tubing as per the problems your having...a gas mig is the way to go...flux core machines are more better suited to the "getting you thru a bind" situation...i have fixed exhaust with a fluxcore machine...it dont last ...zap!
Reply:Also - the only way I ever got those machines to run with fluxcore or hardwire was to turn wirespeed all the way down and turn the amps all the way  up... give that a try .Johnny
Reply:Originally Posted by JohnnyWeldAlso - the only way I ever got those machines to run with fluxcore or hardwire was to turn wirespeed all the way down and turn the amps all the way  up... give that a try .Johnny
Reply:ill try all of your suggestions and let you know the results.
Reply:I had trouble with my MIG 100 and replaced the wire feed assembly. It now works 100% better than it did when it was new so they may have had a few bad drives. I use low amps and 7 on feed and get good welds on tubing with mine.