Ok, I thought I would throw all of my brain at this problem.........it bounced back at me and poked me in the eye.
Here's what I was thinking, some garbage between the inner and outer rocker was outgassing when heated up by the welding.
What if that stuff had already been precooked? Bernzomatic to the rescue!
So I take that little blue flame and heated the next area to be welded. Smoke was coming out and I'm thinking, "Yeah baby". Surely we just have a dust between the two panels now, right?
Ah no........so, screw it. I'm just going to give the old overlapping spot welds a try. And it's a popcorn fest still! DAAAAAAMMMMMMIIIIIITTTTT!
Luckily this came to a grinding halt because I ran out of wire.
Off to the store. Got the wire, ran it through the machine and was ready to give it a go again.
Same thing! DAAAAAMMMMMMIIIIIIITTTTT! Then i noticed the brown residue around the welds, I started crying here.......I shut the gas off when I ran the new wire and forgot to turn it back on. Weep for me Argentina.
By this time I had already welded the tubes and was just working on the pinch weld. So I finished off the overlapping spotweld thingy.
Then I ground a small area of the gasless spot weld area (wife's home, no long term dressing now!) just to be sure it bonded to both sides. I'm good luckily.