Ya it definitely didn't like welding the galvenized pipe, especially since I didn't grind any off at all. The wire would just push against the surface for a milisecond before arcing,(almost like faulty ground, but it wasn't) just enough that the wire would heat up and break further up, even on higher voltage. The way that worked best was to begin the weld somewhere down on the 1/8th inch plate, then work up to the pipe. Unfortunately this added much more weld overall than I would like.
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