7018 Issues.. possible arc blow?

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Im running my stick welder DCEP at around 90-110.  Im welding 3/8 steel with a 7018 excalibur 1/8 or 3/32 (for some smaller stuff)I was having issues before and bought new leads for the welder (The old were aluminum)It welded great at first on the horizontal.  Occasionally it would randomly just start popping or cutting out in the middle of a great weld.at 100Amps the 7018 excaliburs are blowing through 3/8 steel.... They act like I am long arcing the rod, even if I shove it deep into the weld.I also just started using a 12$ magnetic ground clamp from the LWS.Im having real problems vertical welding with the 7018. Im doing vertical up as spec'd by lincoln for these rods.These rods also keep having the arc die mid weld, you start running the bead and the arc will die, or the slag will just jump to the rod and put it out.  (Im doing a lot of out of position welding on a truck we are building.Also, the metal seems to drip when I run a vertical stinger and clump at the bottom.... Ive never had these issues before...This welder is so un-predicatble.What could be the issue?
Reply:I never cared much for the magnetic ground. I have always used the 250 amp clamp.  Move your ground to a different spot and make sure the steel is clean. Clean where you are welding and clean where the ground attaches. Kinda sounds to me like the amps are to low. Maybe kick up the heat a little.  For 1/8" rods I would start out around 120 amps. When the heat is to low you will spend more time in one spot trying to get your puddle to build up. That will do more harm than good. Also you fight trying to keep the arc going with low heat.Operating Engineers Local 3Lincoln SA 200Victor TorchDewalt Grinder10 lbs SledgeWhat more do ya need!
Reply:1. i'd take the cover off the welder.  2. weld w/ it.   3. unplug it.   4. feel the wires, cable connections, switches, terminals, parts for excessive heat.     sounds like welder machine problem
Reply:If your workpiece is too small to move the ground point enough, consider making a Y ground cable with TWO ground clamps and put one on each side of the weld. To first order the magnetic arc blow forces cancel. I had to do this welding up my test coupon to get certified years ago.metalmagpie
Reply:I just passed my structural check test to renew my CWB ticket. I used excaliber rods for the test. The rods are top knotch. If your slag is jumping out into your arc as your welding, you may be using incorrect rod angle. Are you pushing your puddle or pulling it? Running 100 amps on 3/8" thick plate should never burn through. Something in your welding technique or machine is not right.JasonLincoln Idealarc 250 stick/tigThermal Dynamics Cutmaster 52Miller Bobcat 250Torchmate CNC tableThermal Arc Hefty 2Ironworkers Local 720
Reply:Not enough amps to have arc blow from the machine but maybe the magnet is having a similar effect? Try a different ground clamp first.
Reply:When doing vertical I had similar issues when doing practice plates. I tried coiling the ground cord on the tube where my plate was attached to and clamped the ground as close to my work as possible. I noticed that I would experience what seemed to be arc blow last third of the plate, the first 2/3 thirds of the plate welded fine. I had the instructor come watch me to see if he could pinpoint the problem and found that I starting to point downward on the puddle making it drip instead of pushing the puddle upwards when I got to the last third of the plate. With 1/8" 7018 I would usually start at 115 and lowered down to 100 when doing a cover pass on a test plate. I would suggest you try a ground clamp instead of the magnet to see if you're experiencing the same results. Hope you find a solution.
Reply:All good suggestions guys.  I thought 110 was too low as well till I realized I was blowing right through the steel and causing Undercut.  I tried slow at first, then I tried faster and faster and I was still getting undercut! on 3/8! at 110AMPS!  I couldnt figure it out.  I had some 7018 AC rods laying around, on DCEP they run great.... What!??!?! I know its a DC machine, its DC stick tig....they burn slow and run steady.... (hobart and radnor).welding leads are 15ft long each, 4AWG (165amp welder)I was using about a 15*-20* rod angle (45*-40* from work piece for vertical)... I even tried a perpendicular angle and it was killing me.The 3/32 rods drive me nuts, they stick and arc dies so fast because of the vibrations at the tip when I strike the inital arc.... I gave up on them.Im not a pro welder, Ive been welding for years and taught myself Stick... ive never had these problems though, on horizontal bench welding, the slag was peeling off behind the welds and everything... perfect.. overhead and its just crazy.Im gonna have to try the old clamp.... I can wait to get flamed by others for the welds Ive done on this project hah.This is the project im doing.http://www.pirate4x4.com/forum/gener...ega-truck.html
Reply:Oh and Im dragging the rod.