Here's the deal. I'm spot welding the chassis wearing an auto darkening helmet. I get a bright flash. So, thinking I had a contaminated weld I grind a new tip on the tungsten electrode (TIG). Try it again and the same thing. So I put a tip on a new electrode, try again, same thing. So I re-clean the tubes and get a new filler rod. Still get the bright flash. So I mess with the controls on the helmet. That seemed to fix the problem for a while. Then it did it again. If I mess with the helmet controls long enough I can get it to work again, but from time to time the problem persists.

Is there something I should be doing maintenance wise that I'm not doing? Anybody else run into this problem? I can be welding along fine and then for no apparent reason get an arc flash. Not a good thing for the eyes, I need to fix or replace the problem post haste.