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I've welded with rods directly from a puddle of water. They sputter and act funny, but they weld. This isn't that, and besides I ruled it out with various types of known good rods.
I immediately suspected (and continue to suspect) the rheostat.
The leads are nearly new 2/0 cable. It seems unlikely they'd be the culprit, but I'll rule them out by trying others.
The rod was new and clean and dry, but of course I tried several different rods from several boxes.
I...
Yesterday I used it for fencing. Running a chop saw off the AC generator and using the welder for stick welding. Settings are coarse adjustment at minimum, fine adjustment at maximum, which should yield about 90 amps. 2/0 cable leads. 1/8" 6010.
Yesterday it worked fine. Today I got to the job...