Ok TBone, here's one.

Well you should be able to use upto 5/64" solid wire as you would be at peak amps on your machine. In reality about 1/16" manual Mig as the torch gets hard to control at about 275amps and it gets warm.

They do make a liquid cooled torch that would solve that problem but most of all of the 1/16" machines that I've seen are either semi automatic or fully automatic. Not to say that you can't manual Mig the larger diameter electrodes but just the companys I work for were set up for automatic orperation.

You didn't give us alot to go on of why your disappointed on using .045. Type of electrode, base metal, joint design, cover gas and flow, position welded or rotated, joint prep, would let us know more about the reason why.

T_Bone

Do you mix your own gas or use premix?

T_Bone

Na I had to see too many Doctors last winter and it set me back a year. I'm going to try this year. I'm still looking at the Tennesse Walkers. did you have fun on your trip?

Geezs buy a new truck and your already complaining...LOL Ok spill it and tell me whats wrong. Did you try the 1/2qt ATF type F per 50gal like I suggested?

T_Bone

Well I've got good news and bad news :)

Good news is if you and your buddy were pulling another 10,000lbs then you would be walking away from him because of your lower gearing.

Bad news is He spanked your butt because your too low geared for your power to weight ratio. You had to drop out of OD, he did too, but with your 4:88 ? when you drop into driect drive 1:1 then your all high RPM.

Your buddy has 3:73/4:10 and has close the same power to weight ratio but higher gears therefor more top speed at a lower RPM than you do.

Add the 10000lbs and your buddy would looking at your tail lites.

Your innercooler tube could have blown off from over boost as at 3400rpm should yeild about 28psi to 30psi of boost. Is the 6.0 still waste gated? I can't remember but if it isn't then you best double clamp the hoses as it will happen again. If waste gated then have the shop check on the relief setting of the waste gate as the 7.3 is set at 25psi.

I also seam to remember reading about a scuffing of the innerpipe coupling that helped along with a glue?. You might want to research this more.

I don't have a problem with my 7.3 PSD blowing innnercooler hoses as I use maximum torque RPM or 1600rpm for pulling loads. I get 14.1mpg pulling 16,000 GCW with this method, recent AZ to Co trip. On a 7% grade that means approx 42mph. In any event I don't exceed maximum peak HP RPM, 2800rpm while pulling near maximum GCWR.

I just did my 15,000 mile life time mileage of 17.2mpg average. Thats with 6000miles pulling 16,000 GCW :) :) Not bad for a F350 DRW!

My son just bought a new 04.5 CDT-600, 4:10, 6spd CC , Swb, SWR. On my test road I held a steady fuel pedal (didn't add fuel while on the grade) at 55mph on the flats and while climbing a small 4% grade.

At the top His Cummins was at 51mph, where as my 7.3, 6spd with a 3:73 ratio was at 50mph. That told me we both would drop out of OD while climbing a 7% grade with being close too GCWR. He would drop out slightly latter on the grade but I would travel slightly faster on the 7% but we're splitting hairs here as there both very close. I was expecting the CTD to top out at 55mph or very close too it.

What shocked me was the low end torque increase of the 4:10 ratio. A very noticeable difference than my 3:73. The CTD has 80ft/lbs of torque over my 7.3.

T_Bone

Something you might try is to back out off the fuel pedal and stay in OD longer if thats possible. You might also consider a US Gear OD unit to give you a double OD. See that 6spd would have worked better since your "racing" as you could have held OD longer. I personally wouldn't be running higher than maximum peak HP design as your engine and drive train componets won't last.

AFT type F lubes the injectors, alot! It cut my injector noise by 1/3. ATF has been used as a injector lube for the past 50yrs that I know of.

T_Bone