Problem sorted,converted to gas CO2/Argon mix and 0.6mm wire, its like a new welder, still not quite upto my plug welds, but managed to sort these with a 140amp arc welder. So jobs agood un.
Yep all cleaned up finished tnight, the small amp arc made a very good jod (for my standards anyway).
The flux cored wire that was rusty I'd bought of Ebay, the guy in machine mat recons it was probably old stock, as it wouldn't of normally rusted inside the sealed bag unless it was old, if you know what I mean.
hmm you never know did they have loads of it, could they have been sneaky needed gasless and transfared the stickers to get rid of what they already had