I agree with the other responders; what I would add is just maybe some more clarification; If you're burning holes through the metal using a reccomended setting(s) then the problem is usually technique (or lack thereof) meaning operator error. Move a little faster so the heat doesn't get so high and "stitch" weld as suggested. Weld a 1/4" or so and skip 6" then weld 1/4" again. Rinse and repeat.
Sometimes you just have to lower the setting(s); who knows why? Maybe you got a 'HOT' machine, or a cheaper grade of metal or it's steel and not "black iron".
Always do a spark test on unknown metals prior to welding.
You can get a good idea of what you're welding by the color of the sparks created when you grind the metal in such a way as to create sparks. I'm sure you can find out more about spark testing on the web.
Last edited by Doug9656; 12/14/2009 7:06 AM.
