I was gonna ask this on another thread, but that woulda derailed poor dudes progress thread so I'll ask/discuss it here. I've been welding for years. Occasionally, I'll get a pretty good looking weld, other times the welder will do a crap job on similar metal/thickness(s) that it worked fine the time before. 1. Most frustrating for me, is I'll be welding along and the thing will occasionally sputter, and will act almost like it's cutting off and on very quickly. I typically release the gun trigger, and restart the weld when this happens. Sometimes that works, other times it'll just happen again a little further along the weld. It's a Lincoln 110v welder that's about 10+ years old. When these things get old what wears out in the electronics that makes it perform less than optimally? 2. Other times (on setting D, the hottest setting) This thing will weld like a sumnbi tch, and will weld the hell out of .125 wall stuff, but will spatter all over the place. Why does it throw spatter all over the surrounding metal? it doesn't happen on the C setting at all. This was welded on my C setting: you can just start to see some of the spatter I'm talking about. These are the 16ga parts to my Frank N pan. Had this been thicker, and the heat been up to the next setting, that spatter on the side wall would be all over the place. What do I need to do to stop that? Also, This is the fully completed Frank N pan. I trigger pulsed the weld to keep from melting through the thinner pan metal. Those little pinhole looking things are not through, so there is no leakage, but it happens every time I weld this way. What the hell is that about?