Best Flux Core welding example to date.

[theKbStockpiler]

I was having issues with a transformer wire welder with it's wire speed being too fast running flux core so I installed a new Wire Speed Controller. It slowed it down a little but I decided to try some Ballast Resistors in series with the motor to see if it would help. The Controller is a Pulse Width deal so I did not want to fool with that.

It looks like most of the issues with using Flux Core with thin metal is the Welder manufactures have the low setting too fast.

I did this as a continual bead and you can see how at the start it lumped up but after some local heat was added the bead flattened out pretty nice. Edit:Both of the pieces of sheet metal are 20-21 gauge.

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My beetle is not competing with your beetle. I have the yellow beetle in my town. There is a red one, a green one ......
Use all safety devices including a mask.

[Maxpower]

I would double check your polarity most welders come setup for gas shielding so when you switch to flux core you have to switch the polarity. This will make a big difference especially on machines that are underpowered.

[theKbStockpiler]

On the topic of the welder issue.

All readings on slowest setting:

-Old wire speed controller; 220 inches per minute
-New wire speed controller ; 160 inches per minute and still too fast.
-2 ballast resistors in series with new wire speed controller 60 inches per minute and perfect for the lowest voltage with a sustainable arc.
_________________
My beetle is not competing with your beetle. I have the yellow beetle in my town. There is a red one, a green one ......
Use all safety devices including a mask.