I've tested the pot every way I know how....directly on the pins and on the plug, on the floor and by hand. Some times I get a smooth reading and other times nothing but that's likely the probes slipping (no alligator clamps). There is full motion of the pot with the pedal and strip of timing belt (no doubt a money saver over bronze rack and pinions of the Hobart) and the micro-switch works well. I estimated the highest amperage to be 100, but the highest reading seen by my buddy was 154A with the pedal nailed to the bottom.
This could be important; Under the hood it seems the amperage tops out at about 100, but a buddy stopped by and he calls out what is showing on the panel as I'm welding. Odd---The amperage doesn't jump to the highest reading when the pedal is floored...it takes half an inch of bead with the foot pedal all the way down for the amperage to finally get to the high point. It seems to start out at about 80A, hang around 100 for several seconds and then jump up in random steps from there. If the pedal is half raised and floored again the same random stepping action happens. It will drop the amps as expected, but step up over time. I don't understand electronics in general and delayed reactions seems to be very abnormal to me.

My first thought was the up and downslope settings were having some kind of effect but it's the same no matter their position.
The pedal reacts the same on AC and DC. All other controls and settings seems to be just fine and the pulse function is something that REALLY works!!!. The plasma cutter is MAGIC!!