Thanks for the tips everyone, the welder is a 220v but I am running it through a 50 foot extension cord. I am pretty sure I have welded with it plugged in directly and still had trouble though.

I am definitely going to replace the liner for starters as it is definitely possible it got beat up at some point or ran over by the cart.


Mr. P Body, you may be onto something as I keep the welder in a very dusty garage and my wire always seems to have a bit of dust on it from storage in the welder. I may start to remove the spool and keep it in the house from now on to prevent contamination, but that would make sense that unclean wire is causing the issue. I feel like it has done it with new wire too, but it's hard to say as more often than not I am welding with a spool that has already been sitting in the welder for a while.