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These are rudeimentary comments from me...1 are you switching the polarity when switching from gasless flux core to hard wire? If not try it
It's just a shot in the dark, but I had a 110 mig that would not weld worth a crap unless it was plugged into the outlet about 2 feet from the breaker box. Tim
I had the same deal on my Hobart 140 volt. Is your welder a 120 Volt or 140 Volt?
They are all 115V, 230V, or 200/230V. 140 is a reference to the amps not the volts.
It's a Hobart 125 with the Hobart gas kit. I can post a pic if you like but I'm looking at manual. Boost, it's frustrating. I've gotten pretty good with the flux core; I can even weld with minimum splatter and things are tight with good penetration. When I started with the gas I was thinking all would be well and good and I could do at least as good as I did with the flux and lo, I started turning out el crappo welds. Looks like I'm using a cake froster, just pouring metal on top of the steel. I have tried all the suggestions save one, to preheat my metals with a propane torch which I don't have. I've wasted too much time farting around with this thing hence I put the flux core back in just so I could do some tacking and keep on going. Nutz has a great idea in taking the unit to a professional but that will cost me a half a day out of my shop to do it which I don't have at this time. Your suggestions?