Here is a picture of what I would consider "Tiny" TIG welds. 
The part shown is of a 1.25" dia cylinder butt welded to a 
0.125" flat. Both are stainless. As you can see, the welds 
are very small - measuring approx. 1/4" long x 1/16" wide. 
This is a produc

bead to be anything less than about 1/8" to 3/16" wide. This 
relatively large weld is somewhat unsightly. I would like to 
get the bead down to about 1/16" wide (or less). I'm using a 
#4 cup on my TIG handle and have tried both 1/8" and 1/16" 
electrodes I'm sure technique must play a part. I've tried 
filler rod ranging from 1'16" down to .035" wire. The problem 
seems to be that I can't get my puddle small enough. As soon 
as I add filler, the bead jumps to a width well over my target 
size.

Any comments on how to achieve this very small TIG welding 
would be appreciated.

Thanks,
Dan (dossdev@earthlink.net)