Mark @ Everlast
Advertiser
Joshua, I have browsed through this thread, and haven't read every word of it, so forgive me if I am backtracking here. From the picture of your welds in DC, it looks as if you have the wrong polarity. I know I saw you having the leads matched to their "correct" color...which if the unit is connected as I think, that would mean you are in straight polarity...and would cause the beads that you see. You need "reverse" polarity to weld DC on most rods. It would also cause the other symptoms you are seeing. Your electrode holder should be in the positive terminal, regardless of the color you see on the plug side. Work clamp should be in the negative. If so, then don't forget that when you go to DC on those small transformer welders you are basically cutting AC in half...and it takes "more" setting of the amps, because you'll max out at almost 125 amps or so DC.