Popping Question

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Here's the deal: I'm still relatively new to welding. A friend of mine who was a pro welder taught me FCAW on a Harbor Freight 90Amp machine. He got me welding really good beads but I now picked up a 135AMP Eastwood machine. This machine I can tell is a lot more powerful and built better. However, when I'm welding it's going "pop-pop-pop-pop" really fast... Almost pulsating. I know this happens when the wire speed is too fast but I turned it all the way down to 3 and it still happens but just slower. If I trigger the welder in the air, I can hear the same intermittent pulsating in the drive motor... So I've tried 3 things:1. Lowered the wire speed.2. Loosened the wire spool nut.3. Loosened the Tensioner.So far, none of these have stopped the pulsating. I don't want to keep loosening the spool nut because I dont want the spool to unravel like crazy.Anything else it could be? Besides this, I'm hearing the signature "sizzling bacon" sound and all seems to be well. Thanks.PS: I'm welding on about 1/2" thick steel L Angle for practice. I know the welder isn't rated for this but its all I can get my hands on and the Harbor Freight did this just fine for practice. I usually do several passes anyway. Using about 6/10 voltage setting.Last edited by TCWelder; 06-02-2013 at 11:52 PM.
Reply:Check the grooves in your drive rolls to see if they are ground correctly,  and see of the diameters are concentric between the OD and ID.Weld like a "WELDOR", not a wel-"DERR" MillerDynasty700DX,Dynasty350DX4ea,Dynasty200DX,Li  ncolnSW200-2ea.,MillerMatic350P,MillerMatic200w/spoolgun,MKCobraMig260,Lincoln SP-170T,PlasmaCam/Hypertherm1250,HFProTig2ea,MigMax1ea.
Reply:Originally Posted by TCWelderHowever, when I'm welding it's going "pop-pop-pop-pop" really fast... Almost pulsating.
Reply:Run it with out wire and if your motor is surging/pulsing and it is new- Contact the dealer. something is definitely wrong with it.
Reply:Look closely at the spool's interaction with its brake. A "rough spot" on either the spool (or the brake) surface as the two slip past one another, will create a periodic increase in drag which the motor must overcome.Last edited by wirehead; 06-04-2013 at 08:11 AM.XMT304 (school)SP125+ (home)HF 4x6 BandsawGood judgement comes from experience and much of that comes from bad judgement.