Having just bought my first welder the other day (Lincoln Handy Mig) I went down to the scrap yard and picked up a variety of metal to practice with. I found a bed frame that I cut apart then welded back together, some thick grill grates, some thin grill body metal (really thin sheet metal that makes up the sides that surround the bottom propane tank area of a grill)
Welding on the thicker metal doesn't seem to be an issue as I can get the "bead" or molten area of metal to move around and work well. It's the thin metal that I'm having an issue with. I'm just blowing holes in the metal when I'm trying to join two pieces. I have the welder set on it's lowest settings, but that doesn't seem to matter.
I'm using flux core wire, so I'm curious if I went to a thinner non-flux wire and a shielding gas, if that would help? I have a truck roof rack that is somewhat thin that I'm getting ready to weld on and I don't want to ruin it!