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[Weld dr]

You should also clean the underside if you are doing a but weld the paint down under is most likely the problem.

[Weld dr]

Show us some pics. if possible. I have done this on some older units took a razer blade and cut it off.
Unit ran fine.

[Weld dr]

Anything is possible but i do not think it would be cost effective 460 would help on amp draw but step up xfmrs are not cheep.

[Weld dr]

I am pretty sure thermal is 1k ohm. The same as Miller.

[Weld dr]

This is a CV output unit not made for stick welding.

[Weld dr]

You are very welcome.

[Weld dr]

They get warm nothing to worry about.

[Weld dr]

I would also go through all connections on the regulator board and clean them also .Make sure you you also check the slides on the two big resistors i have seen those rust up. But looking at some of those connections i would do a clean sweep on all connections on that unit.

[Weld dr]

That diode is bad i would replace it.