Hobart Handler 135 question

[SAR Tracker]

Have the above welder, using flux core .035. Welds look like hammered dog sh@#. Lots of porosity, weak weld strength, generally unacceptable. Welding .125 steel. Done a lot of welding in my past, with excellent results with this combo, but not a pro. Using chart on the welder, settings are matched for .125 steel. 2 questions: Could age of wire be a factor (several years old, but stored inside in the welder above 40F. Or, could distance from outlet (150'+ on extension cords) cause a drop in voltage enough to bring me grief? Ready to bust out the old Lincoln stick welder with some 7018 and go medieval on it's azz.....

 

[ken erickson]

Not sure of your extension cord wire size but with 16ga wire, 150 foot your looking at about 20% drop in voltage. I would say that very much is a concern. Try running the welder at the voltage source if possible with the same flux cored wire and a few .125 test coupons and see what your results are.

 

[Trimley]

I also would think the extension cord(s) is the issue.

 

[jaxs]

I'm with Ken about extension cord being primary suspect. Is it possible you forgot to switch polarity after the last gas shielded job? If the wire isn't rusty I doubt storage effected it.

 

[North Idaho Wolfman]

Have the above welder, using flux core .035. Welds look like hammered dog sh@#. Lots of porosity, weak weld strength, generally unacceptable. Welding .125 steel. Done a lot of welding in my past, with excellent results with this combo, but not a pro. Using chart on the welder, settings are matched for .125 steel. 2 questions: Could age of wire be a factor (several years old, but stored inside in the welder above 40F. Or, could distance from outlet (150'+ on extension cords) cause a drop in voltage enough to bring me grief? Ready to bust out the old Lincoln stick welder with some 7018 and go medieval on it's azz.....

All of the things you list could be an issue, aloo if the unit has the ability to reverse polarity that could be your issue.
Flux core is the opposite polarity then gas welds.

 

[SAR Tracker]

Haven't used it as a gas welder, so I'm also leaning towards VAC drop. Also picked up a new spool of .035 just in case. Will report back. Thanks guys!