Ok been an amateur welder for about 3years now. Im using a hobart 140 (120v) with 75/25 gas set at 20cfh and .023 wire.

Ive welded patches and floor pans and many other misc things with some success and some crap. I love the welder, for the price I thought it was very good and does all I need to do.

The main question is: once in while when I start my weld the wire starts to melt back on itself and not place itself on the metal. It leaves glowing little ball of material on the wire and you have to start again. This is VERY annoying and often causes a bad next weld. What is causing this? Unclean metal? Ground to far from weld? (maybe an amateur )

Another thing would it be advantageous to switch to 0.030 wire for panel work?

Enlighten me so I can be a good amateur!