As far as the tip- that's what's got me puzzled. It feeds smooth as glass out of the tip- which I replaced 1st and found no difference. It only pulses while actually welding. I cleaned the ground spot, snugged up the cable to the clamp, and made sure it's tight in the box. When I get back to it this weekend I'm going to try a clean piece of steel on the bench and see what happens. Thanks for the tips guys!
Working on old cars teaches us patience... and every curse word imaginable!