I was able to do a little more troubleshooting on my welding machine. Turns out the flow meter was way off, I purchased an external flow gauge to find out. It requires roughly twice as much air to achieve the correct CFH. With running the machine in DC you dont notice it as much but while in AC on aluminum it was horrible. Below is a picture of the 1/2" bungs I welded on the bottom of the intake, they were very rough and I cleaned them up a hair after the machine was operating normal again. Also laid down some SS welds to see if they would be better than before with the correct CFH and they look a little better than before. Did a little practice without a back purge on some 304 tubing to do a little practice for my upcoming exhaust build I'll be doing soon. If you are unaware, you need a purge or flux to protect the back side of the stainless welds from oxygen due to the stainless being reactive while welding, it will look like crap as seen in the photo below.
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