[Brettm357]

What am i doing wrong if possible

https://imgur.com/gallery/tm2MD

[Poland308]

The rough edge on the top piece is probably from a combination of moving too fast, running too hot, or lack of cleaning of the mill flake. Otherwise it looks pretty good. You could try slowing down or running several beads to get the desired look. If you want to weld it in one pass then you may need to change wire size, so you can add more filler faster. Gun angle can also come into play on a lap joint. You could also try favoring the top edge more than the center of the joint. How thick is that metal?

[Brettm357]

1/4 inch using gasless flux core 0.045 (1.2mm) size powered by 205 amp machine with wire speed set at 170ipm

[Brettm357]

Slowed down a little made sure wire was on front edge changed gun angle

https://imgur.com/gallery/VpGd9

[Poland308]

That looks a lot better! Nice

[Brettm357]

On the weld i noticed little pits in the weld at first i thought i was causing it on previous welds when i was chipping the slag but this one i did not chip - is this a form of porosity or is it normal

[Poland308]

Took a closer look and I see what you mean. Grind into the weld and see if there are more holes under the surface or if it's just the one. Is there any chance there was any oil residue on the metal?