smokey_truck,
Just for the record, Jim Bow speaks the truth...it isn't the welder or the fact it came from Harbor Freight, it's the process that is difficult with sheet metal.
Flux core is a tough gig on thin materials, solid wire with shielding gas (MIG) would make life much easier for you, but your bank account wouldn't be as fat.
Stuart
Last edited by atomarc; 09/10/2008 5:20 PM.