stick welding old thin header tubes?

1. The issue with arc welders is that many of the are AC arc welders and the alternating current makes getting a decent bead very difficult.

2. The diameter of rod is too thick. I don't know if anything thinner than 1/8" is available but if it is, you should use it. Thicker rod requires more amperage, which means your more likely to burn through.

3. Flux core wire is really only suitable for heavy material. For 16 gauge tubing you should be using .023 wire with 75% Argon and 25% CO2.

4. You should be able to get decent results with Mig though you need to use gas along with it.

Regards,

Joe Dokes