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!

 

[North Idaho Wolfman]

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!

Drop to .030 and you'll do way better, O35 is at the limits to what that welder wants to run.

 

[SAR Tracker]

Drop to .030......

Thanks - I'll try that also.

 

[chim]

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.

The ol' reverse polarity thing got me once. Took me a little head scratching to understand why my beads looked more like volcanic rock

 

[mcmxi]

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.

The owner's manual provides some extension cord guidelines. 14 AWG for up to 50ft, and 12 AWG for 50ft to 200ft for the 115 VAC model.

I like your idea of running the welder without an extension. Quick and easy verification.

 

[mcmxi]

Drop to .030 and you'll do way better, O35 is at the limits to what that welder wants to run.

I recently bought some .035 solid wire and it was more than $50 for a 10lb roll. The chart below shows that the welder should be able to handle .045 flux cored wire, but of course, that's not based on a 150ft extension cord of unknown wire gauge.

 

[jaxs]

The owner's manual provides some extension cord guidelines. 14 AWG for up to 50ft, and 12 AWG for 50ft to 200ft for the 115 VAC model.

I like your idea of running the welder without an extension. Quick and easy verification.

Me to. Process of elimination usually make's it to finish line sooner than going long distance interweb route.

 

[SAR Tracker]

OK, tried no extension cords, changed to .030, changed from straight to reverse polarity and back, several different setting combinations, all to no avail.

Switched over to stick, and finished the job with 7018. Thanks for the input. Always helpful to realize that I'm not really THAT crazy! LOL.

 

[North Idaho Wolfman]

I have much better luck with Gas Mig then I do with flux core.
I have been working with some .065 steel square and have found that I needed to bump the voltage and the wire speed a bit to get better welds.