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Did you wire wheel clean the back side of the sheet metal in the area of the weld? I know that if there is some residual paint or rust on the back side it'll outgas and blow the molted metal out. Also, I was using a copper strip backing (others have used aluminum strip) on the inside so that the MIG wire had something to "hit" on initial strike/start of weld...did you use any backing like this?
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