Welding woes...frustrating!!

Flux core wire is especially sensitive to proper hand and nozzle tip position.

When doing a vertical weld with flux core, you're going to get the best welds going from bottom to top. Going from top to bottom causes the flux to drip down into the puddle causing an "overlap" condition where the weld does not penetrate. Try holding the nozzle so that it points slightly upward, then start at the bottom and weld towards the top.

For a horizontal weld, tilt the nozzle backwards slightly from the direction of travel and "pull" the puddle. Flux core wire does not like to have a puddle "pushed".

And above all......THE MOST IMPORTANT THING ABOUT FULX CORE is to be able to tell molten flux from molten metal in the puddle. Flux will NEVER tie into the metal....only molten metal will tie in. So being able to recognize and control the puddle is the key to the whole deal.

I might also add that you will have MUCH better results using a tri-mix gas and solid core .023" wire....especially for Sheetmetal and most general automotive welding jobs. It's also MUCH easier to get good clean welds.