Help welding thin Aluminum PowerTig 250EX

[joshtodd1984]

Josh, been checking on your unit and trying to figure out the confusion. Don't worry, you WILL be taken care of. I need to fill in a couple of blanks here. When did you buy it? Where are you located? And can you post up a picture of your spec panel ( the graph on the side of the welder)?

Welder was purchased in 02/15/2015. Was purchased under my g/f's name as it was a surprise gift. Order #59648366. This is the 3rd time I've used it in a/c since owning it. The first time trying something this thin in a/c. I welded razor blades together in DC so I'm fairly confident in my abilities and knowledge with setup.

I assure you the arc gap is not excessively large. If for some reason it appears that way, it must be attributed to trying to capture the unusual problems I'm experiencing on film. I would not contact external assistance over something that would be considered a rookie mistake. That is one of the very first things i ruled out of the equation.

This is beyond my realm of knowledge. I tig weld every day as part of my scope of responsibilities as a Maintenance technician at a major auto manufacturer. I've tried everything that would be considered elementary to most of the welding community.