welding 1/8 aluminum with .35 wire and burns through.

[james malone]

Should i use smaller wire?.25 would this be suffice

[cruizer]

no, just turn down your voltage, however you didn/'t mention the power source, nor spoolgun or much...

[CODE4]

I assume you mean .025 and .035 filler.

If not, then stop using filler in excess of 1/4" thick for base metal that is only .125".