Original poster here. Thanks for all the suggestions. Going to start with the ground. I have a 1/4" sheet I am setting the parts on and clamp the ground to that. It's pretty rusty so I spent some time on it with my belt sander and when the weather improves I'll give it a try. The rust is a known problem, so it makes sense to start there. The shop was wired by an electrician specifically for the welder so I don't think mis-wiring is an issue. I have some 7018 rod, so I'll switch to that from the unkinown rod that came with the unit. Thanks again. I hope you won't have to hear from me again!