Update for those who might have the same problem. The tube on the spool gun was a bit loose. I took the gun apart, took out the drive rollers to get access and tightened the nut on the tube. Reassembled everything and it welds great. Moral: If your tube starts wiggling, tighten it up!

I've been using my Hobart Spool Runner 100 for more than 6 months with great results. Suddenly, today, it started burning wire back to the tip almost instantaneously. No change in settings, just all of a sudden. Wire is 4043, .030. It feeds fine through the rollers, but when you start welding now, i...