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Tom, I had a problem like that with a Wen gun, the tipe had cracked in 2 at
the end and was an open circuit some of the time.  never had that problem
with  a weller that has a heavier section at the tip.
More likely the problem could be some corrosion or chemical at the lugs
that isn't passing the current.
Just saw the reply from K3MM, I would recommend that as a replacement as
well, the large butane irons will really out out the heat.  Some can also
be used a small torch as well.
73 Jim
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