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Re: K/5 Tahoe build thread
Are you using .030 or .035 wire? If .035 you should switch to .030.
Even with .030 butts will be a struggle especially if there are gaps during fit up. If I were going to use flux core I'd try one of the two types of flange methods shown below. Manual and pneumatic tools are available for each and are pretty cheap. The additional metal in the weld should eliminate most of the burn through. The lap type is the most forgiving. The type that rolls the edge 45 degrees provides a nicer repair IMO as there is no lapped joint to hold dirt and moisture, however you'll have to have your fit up near perfect.
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