Deep Six 
Well,
If you can post those pics I've requested, please do, as people here can see things in them that you don't, which is why you're requesting our help. But we need your input sometimes, like with the pics. I mean, apparently your expert on the scene there hasn't solved your aluminum issue. So, we could use more input, from you, like pics of the "different setup", etc., i.e., don't keep us in the proverbial dark while continuing to ask for help.
Otherwise, a common rule-of-thumb with aluminum to to be able to get a puddle going on aluminum in about 3 seconds, or less. And on 1/8" sheet that is an easy thing.
So, with aluminm, it's better to hit it with a lot of amps up front, watch for that glint of a puddle, then stab or dab, then withdraw the rod so it doesn't "evaporate", then move ahead, repeat, and taper off the amps as needed.
You see, if you use too few amps up front, you overheat the metal without forming a puddle, then the metal drops out.
"Three seconds", or you're doing it wrong, e.g., set the amps at the panel for more than the 1 amp per thousand rule. At 100 amps you're undoubtedly dwelling too long, and just making soup.
And, is your welding lid adequate enough to allow you to see the arc and the subtle start of a puddle in aluminum?
I mean, try doing some tacks in aluminum, with a dab of filler. If you can master that, the rest will follow.
Originally Posted by Deep Six
