Hi again you guys, sorry for the mouthing off in here, thats actually why i quit welding proffesionally... Travelling around 285-300 days every year, i started talking to persons in my social life, the same way i did, when in charge of 10 indian og arabic welders, in order to get things done... Shouting and "pulling rank", sorry bout that guys !
(Nope didn't work for BP ! Worked for an independant Danish contractor, that "rented me out" so to speak, to other companies around the globe, thoug never BP the best i can recall)
Anyhow, what i meant was: Fowler you say the weldments become blobs and as i understand it, they don't penetrate both pieces of material that you're welding together, the way you wan't, correct ?
If that's the case, then maybe you could try playing a bit more with the settings on the welder, and also one more thing kap'n Crunch mentioned earlier, clean the welding-place on the material propperly before welding, it does have a great deal more to say, than you'd think first of !
The reason is, that if one piece of steel is a bit rusty, and the other piece is new blank steel, they won't absorb the heat from the welding at the same temperature point, rust for instance, acts like a sort off temperature insulation, if you would.
Thus you'd have to weld longer time on the rusty part, to get penetration, then on the blank steel, thereby leaving huge amounts of welding material and creating blobs.
But mainly i think you might just wanna turn up your welder a notch or two, on the amps setting, cause i think you're simply not having enough heat on the gun, when youre welding.
I know that often requires you to move the gun a bit faster, and then not having the same experience some of us have, i know that scares some people of a bit, because it gets harder to be accurate, the faster you have to move the gun.
I'm also wondering one thing: Do you use one hand or both when welding ?
Lastly one thing i noticed, especially around two materials with different wall-thicknes, and some places also different profile, you have huge blobs.
Since nobody has shown you anything, maybe it would be ok to suggest, that you keep the heat of the welder, a bit more on the material with the thickest wall, in order to get the welds you want.
The thicker the material, the more heat it needs to get propper penetration, but if the opposite material is thin-walled, you'd risk getting burn-throughs at that material, so keep the heat mostly on the thick material.
I teach shop-class myself on a private school nearby, and the three most common mistakes to the best of my experience, are as follows.
MAIN REASON:
The students are impatient, and more eager, to get theire things out on the field for a good time off bogging and racing in the dirt, then getting the work done propperly. Many times that result in broken down vehicles, from crappy welds, and they have to go back to the shop for repairs. Instead of taking a few more minutes when fabbing things in the first place, and then have lasting fun afterwards.
And YES, i DO understand that shop-class isn't that many hours pr. school week, and off course we want to spend more time driving, than making, those darn fun vehicles.
Next:
They don't try out there welding settings on two pieces of scrap metal, before welding on the cart/buggy. Many a time, the setting isn't correct, and the welds get the way you'd expect as a direct result of that.
Lastly:
Many people seem to think, that a welding gun/grip, is supposed to be only held by one hand. If at all possible, always use one hand to operate the gun-handle, and the other to support it. It gives you a lot more of the desired accuracy, and makes it a lot easier to make great welds. A hunter wouldn't shoot a riffle or shotgun with just one hand, not if he expects to hit anything at least !