anyone else thinking it's not a good idea to 'learn' to tig weld al on lifting eyes? no offence but what if that ---- breaks off and drops the heat exchanger on someone. I wouldn't want that on my head.

 

Dumb question, but are you forming the little ball shape at the end of your electrode before you start? If you dont it is a bitch to start

 

If you have a torch handy I would preheat even if it isn't what is causing your problem. It will make it a ton easier to weld, and you wil have a lot less chance of the start of the bead not "looking" as pretty as the end of the bead. Since you won't have to worry about changing your travel speed as much in the process.