Cyclone ---
I've read your post about 5 times and have yet to comprehend what you're saying. My initial thought was that you're telling someone they should add up the thickness (gauge/dimension) of both pieces you're trying to well and then set your machine accordingly. I.E., a butt weld joint - of two .125" square tubes - should be welded at 250 amps.
Dude! Couldn't be further from correct.... So I don't know what your post is trying to say because I must have missed something there.
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