Better alignment seems to be my problem. I have started to take a considerable amount of time up front making sure my fitment is the best it can be. I would say 90-95% of my problems have disappeared. Thanks to everybody that took the time to reply to my post!

This is pretty typical of what I am getting. Usually one side will sand down fine. Filler is 308/035 @ 40 amps

Thanks for the help. I will get a couple of pictures up to help describe my issues.

As the title describes, I am welding 304 Stainless .065 tubing with back purge. My question is how to control the distortion (low areas) on each side of the weld. This particular customer requests that I sand the weld smooth for polishing. That creates problems with the low areas. Thanks in advance ...

Not sure I should add any gas to the fire, but I saw this post before all of the fireworks and bought the square. Actually impressed with the quality. Time will tell, but for now all good.

Love the tig finger but I was always adjusting it. I added some Scotch glass cloth electrical tape (Good to 356 degrees) to the finger after it was adjusted and now it stays together.