[53LEDSLED]

i can MIG it no problem but when i try to TIG it, it starts popping when i carry the puddle to the old metal. both sides are clean and rust free. to get a better idea of what im welding, take a look at my project journal.

[powerrodsmike]

Are you trying to weld over lead? That will make it next to impossible to weld.
Keep in mind also that metal is somewhat porous when it gets rusty. Even when you grind the rust off there is still a bunch of impurities and crap in the metal. you might want to try an acid metal prep wash. I believe they have them that are weldable.
Also, I use S-6 rod, as it gives a little extra weldability on old crusty metal over the S-2. You can buy it on a roll for a MIG as well as in 3' lengths to use with your tig. I use S-6, .035 mig wire alot when I'm TIGing thin sheet metal.

I would think that your settings should be DC- ,30-40 amps,15- 20 cfh argon, .040 or 1/16" electrode (ceriated or thoriated), and start with a large gas cup. Work your way down in size if you want , but don't let the gas halo get too small. try backing up your weld joint with a peice of brass, copper or aluminum, it will keep the oxygen from getting to the back of your weld.

Hope this helps, mikey

[53LEDSLED]

no its not lead. my settings are exactly like you said.

[powerrodsmike]

Try backing up your weld with a non ferrous metal. I have even used tinfoil.
Just try it to keep the back of the weld shielded from the air.

And try washing the steel with some metal prep. I think there has been a ton of threads on that subject. I would use something designed for the purpose, as alot of home chemicals are not buffered properly and your weld could suffer hydrogen embrittlement. Toilet bowl cleaner is not ok.

To be honest though, I have never had to do anything other than grind the steel clean.

Hope this helps, mikey

[53LEDSLED]

thanx mikey

[powerrodsmike]

You could try a little sandblast action on it too or a fresh grinding disc..
Sometimes grinding with a dirty disc will drive evil, weld hindering crud into the surface of your steel.

Mikey