Have you messured the gas flow at the torch? I recently experiensed a small gas leak in my tig torch, and had the same issues you are having. Other than that, I would say that you are either welding to hot (slow) Have you tried just melting a joint with no filler rod? Just to see how it turns out? B...

The Hobart I do not know. (Hobart is unusual in Norway )

But Hypertherm I could strongley recoment.

Ok they cost a bit, but it is one of the best plasma cutters out there.

Good look with your project.

And what Jody said about the pictures +1

I have to go with what Canuck said. Buy yourself a used Tig machine with ac, I think you would be better off. Remember that you could weld down and up, up and down and even upside down with a AC Tig. When you talk about building boats, that is the way to go. I just sold a Fronius ACDC Magicwave 300a...

When I weld solidwire stainless I always use 98/2% gas.

And I havent tried to purge with an other gas than the one that I weld with, and I would bet that it is the safest.