Thanks for the replies, its appreciated! @Tweake: I’ve also had good results with the exact same filler wire, I dont know if there is a possibility that good and bad wires are in the same package but yeah….ive seen crazier things so why not. :roll: my idea with the #8 cup was that because of everyth...

I’ve also had the same problems when welding 5754 base metal while using 5356 filler wire, everything else was about the same as the setup above. It was a 1/8” thick undertray of a car and I had to fill up some bolt holes (drilled them out to eleminate any junk), and 2 small cracks (used a jigsaw to...

..

When I’m welding aluminum I often get a lot of little gas bubbles that, for the most part, dont appear on the surface but only when I grind off some of the weld (buildup welding) It happens when repairing cracks in automotive wheels and on thin 1.5mm sheet, but I suppose that has to do with oxigen b...