Hi, guys & gals!

Just a heads up to maybe save folks some trouble one day. Had some serious trouble with my wonderful old Millermatic 35, very porous welds. Beads looked all bubbly like lava. Way beyond pinholes, more like bubbles and craters. Tried every adjustment, no good, always the same.

Took the Tweeco gun lead loose and found one o-ring missing and the other one split through where the lead hose connects down at wire drive motor. Replaced, tried her again, same problem!

Checked, cleaned and reconnected ground clamp wire and cleaned clamp jaws, checked all the Tweeco gun hardware, fittings and parts, replaced tip and stuff, cleaned all the plug-in taps. Had already replaced main contactor for another problem before this. Tried various methods of shielding the work area, cleaning the metals super clean by grinding, brushing and even emery cloth followed by solvents and acetone: same thing no matter what, little Mr. Bubbles for welds!

Machine had been stored outdoors under heavy tarps in a very dry, high desert environment. Well I finally picked up another spool of JW Harris ER70 wire and stuck it in: PRESTO-CHANGEO! Instantly back to gorgeous smooth beads, a joy to behold, YEEEE-HAAAAAW!

The 2 year old spool of JW Harris ER70 looked perfectly good, no corrosion or apparent contamination of any kind even on close inspection. Regardless of what it looked like, that was the problem: contaminated wire! Considering the very dry desert environment here and still getting contamination or corrosion, it seems best to remove your spool of wire and store inside if machine is stored outdoors under tarps or in a somewhat open area for any real length of time. Saves a lot of hassles and a chunk of change too!