i wouldn't grind it passed 2.5x the length if you don't have to but that is probably not the issue as long as the collet is making a good seal... i would check the diameter of the tungsten and collet to make sure the are the same size because that seal is what keeps the tungsten cool on air cooled torch... without knowing the diameter of the tungsten it's hard to say, but depending on the diameter of the tungsten you could be at max amperage for it... 80 amps means it would have to be pretty small like... 0.040 diameter. That could cause the end to ball... hope this helps... btw miller's website millerwelds.com is an awesome reference for all things tig welding... they even have a free TIG handbook download
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