Ok, did some more testing a few hours ago. First I pulled the replacement liner and blew out the gun cable with compressed air, nothing came out, it was clean. I hooked the linerless gun cable to the machine, turned on the gas and checked for flow, it was good. Re-installed the liner, and the tip (no wire in the liner) checked for flow, good again. Fed the wire into the liner and figured I'd do a few test welds, here are the results.
A multi pass fillet weld done last weekend without porousity problems (yes I know its very ugly)
Single fillet weld done last weekend with out porousity (yes I know its very ugly)
Lap weld done today done a few hours ago, porousity at start (left side) smoothed out at the end.
fillet weld that started alright but got nasty for the remaining 2/3rds.
fillet weld, 2 starts, both started ok, then got nasty at the end.
Definately leaning towards the gun cable here, I did a leak down test on the hose and reg. Turned off the unit, without bleeding down the pressure and watched to see if it lost pressure over 15 minutes or so, no noticeable leaks (at least up to the machine solonoid.
For those that asked, I have not posted a machine brand because I dont want the manufacutrer to get a bad rap for a mistake I might be making. The machine is under warranty so I will take it up with them once I have a consensus that its not something I am doing wrong. Thanks again for the input and help.
Chris.
Chris.