My regulator was set at 75psi. I was building an aluminum welding table as my first project, on my first day welding aluminum ever. I started and stopped a lot and at high pressure, the initial gas burst was a lot more volume than at the proper pressure, which is 25psi. My solenoid had a sliver of cardboard keeping it from closing all of the way. I drilled the rivets out to get it apart and threaded the holes and replaced the rivets with machine screws. Other than the foot switch being a little iffy sometimes, my 160PI is amazing. I thought I might need to upgrade to a bigger one but it's just awesome.
Someone had posted on the longevity forum your gas meter adjustment of the calibrated pressure diferential and I was wondering it it did improve your gas useage at all what your end pressure is now and other opinions you may have about changing the gas regulator, as I am finding that even though I am using a considerable time tig welding the gas useage seeems to be inordinate compared to my mig welding time and a 130 cf of argon should get me about 8.5 hrs welding at 15cfh.The change in regulator pressure should not have made a big difference only if you do alot of stop starts as the orfice can only flow so much per hour and keep the torch line flow in the event the line is bent which is why I have questions as to useage improvements.
Your assistance would be appreciated
Also how was your solenoid repair, what was removed, as Simon has recommended this repair for myself.