Okay, this is the same issue as Dacro's, except using the HH 135. Today I did about 36" worth and it sizzled like frying bacon! I was happy! Later in the project I couldn't get 1/4" to go right! What the heck? spitting and sputtering. Same metal. All freshly cleaned. Good ground. Same welder (me and machine.) and it goes to pot. Took everything apart at this point. It was either that or pitching it down hill to the creek. The drive wheel groove was a bit filled up with the flux and I cleaned that out. Checked the wire to it and the wire does not fit, which I feel is correct. I suspect the wire wants to ride on the groove edges rather than tucked into the groove. Stripped out the cable, too. Layed it on the floor and lays straight. Rolled it back and forth and it shows no kinks. Did the compressed air thing and no air wants to come out. Shoved solid wire through and some flux (naturally) came out. Kept rodding away at it and aired it out some more. The wire slides through quite nicely. Reassembled it all and checked every step to make sure there was no binding. All was well. Even lightly lubed the plastic spool stem to prevent sticking. The spool tension nut is just barely on. In fact, at one point I ran it without the tension spring. Holding it to the air the wire comes out nice and free. When sitcking it to the metal it starts the darn popping sputtering again. Two Excedrins later I'm typing to you before we hear the splashing sounds in the creek...
Any suggestions? Give up welding? Hire it out?
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