Worst Welder on the planet

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I really want to be a good welder, in fact back in the day I could do alright with a stick but for some reason I can not get dialed in to weld sheet metal with a mig welder. I'm using a flux core set up and welding .18 mm sheet metal. On the high setting I'm blowing right through the metal and low setting (in fact on both) it just seems to gob up. Nothing smooth no matter what I seem to do. I think I must be using the wrong settings and or wrong wire. right now I have the .35 wire on. Can someone please tell me what the right set up would be?Thanks!!!Bob
Reply:Originally Posted by daddiosquaredI really want to be a good welder, in fact back in the day I could do alright with a stick but for some reason I can not get dialed in to weld sheet metal with a mig welder. I'm using a flux core set up and welding .18 mm sheet metal. On the high setting I'm blowing right through the metal and low setting (in fact on both) it just seems to gob up. Nothing smooth no matter what I seem to do. I think I must be using the wrong settings and or wrong wire. right now I have the .35 wire on. Can someone please tell me what the right set up would be?Thanks!!!Bob
Reply:You're right. It is 1.8 mm and .035. Should that work?
Reply:Originally Posted by daddiosquaredYou're right. It is 1.8 mm and .035. Should that work?
Reply:Trying to weld that thin a material with .035 fluxcore wire is an exercise in futility.Get yourself a bottle of C25 (75% Argon, 25% Oxygen) and a spool of .023 solid wire.  It will make your life a lot easier.Do not attempt to weld an entire seam.  Alternate your welds (1/2"-1") down the seam.  When the heat starts to build, move to another weld.  Then go back as the metal cools and fill in.Just my .02Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:Am I getting it converted right? 1.8mm is .0709" or almost 14 ga? If so, that should be very easy with .035 flux core if you set it up right. I would even run that with a 3/32 6010/11 without even blinking. Just make sure your polarity is right and start with your door chart settings and adjust from there. If it is 14 ga, longer welds will be easy as long as you keep moving. The blowouts occur when you are staying in one place too long. Moving is the key to running thinner stuff. When you stop or slow down too much, it is all over. The wire isn't too big. I have run tons of 16 ga with .035 f/c. .035 will handle down to 18 ga or even 20 if you hold your mouth right. Many times, the larger size wires will run thinner stuff a little better. The large wire will help absorb some of the heat allowing you to weld the joint with a little better controll over the burn through. Of course, you have to pay more attention to the weld. You don't want the weld to be too cold and have a lack of fusion. If you just can't get it with the .035, try .030...it may just help.
Reply:Originally Posted by SundownIIIGet yourself a bottle of C25 (75% Argon, 25% Oxygen) and a spool of .023 solid wire.  It will make your life a lot easier.Just my .02
Reply:What are your settings for running the wire?  Have you checked to make sure that your polarity is correct?  It should be DCEN for self-shielding flux-core.  Also, some pictures might be helpful...
Reply:Originally Posted by DDA52Ummm.....I believe an edit is in order.  C-25 doesn't have O2 in it.....CO2, thus the "C" designation.  But we knew what you meant.
Reply:I've never used flux core on sheet metal but commonly use 0.035" wire and a commercial gas mix....argo shield I believe it's called, and have had great success welding down to 18 or 20 gage. Vertical downhand whenever possible...around 18 volts.14 gage should be a breeze.
Reply:You guys are missing an important part of this puzzle, one which he has not told us. He said he has the same problem either on High or Low setting. This means he is using a very rudimentary, HF style mig welder. This means no switching to gas mig, no chance of running .023 wire. Daddiosquared, I personally doubt that you are going to get much good welding with that kind of particular machine on thin sheetmetal. There is no real adjustment to it, and it has very primitive arc stabilizing control. You will be able to weld stuff from .065 to .185 with it, but the results will not likely be a nice smooth bead. The only thing you can do is clean the metal, and practice.And then, after so much work...... you have it in your hand, and you look over to your side...... and the runner has run off. Leaving you holding the prize, wondering when the runner will return.
Reply:I had an HF style flux core welder (worse than HF actually lol) and it broke so much I ended up "modifying it" a bit to make it work for me a little better.  I wired a rheostat into it eliminating the high/low switch and it really helped me dial the machine in for certain situations.  Not sure what type of wire you are using but my machine came with some wire that didnt work at all and when I threw some lincoln innershield .035 it worked a million times better.