Hi All,
I agree with the other posts as to what your problems may be, and will add that the popping could also be caused by using the wrong style of tip. Some tips manufactured by a company other than the torch manufacturer will fit other torches, but will pop. As for the thin stuff, such as 1/8" thick, I use a 000 tip, with the oxygen set on about 20 psi, and the acetylene set on about 3 psi, which will result in a long, quiet flame. Also, on thin material, tilting the tip towards your cut line as you cut helps too. Generally speaking, the thinner the material, the faster the travel speed. A lot of people more or less melt the steel rather than cut it because they tend to crank up the gas. A torch doesn't have to sound like a jet engine. If you find a chart, have a steady hand, and follow the oxygen and gas settings, you can get good results with minimal slag that can very easily be scraped off. Just like welding, there's more to it than just firing it up and going at it. Rather than a helper coming behind them and grinding, I have my guys grind their own cuts. Pretty soon, I see them looking at the charts posted around the shop and their cuts improve dramatically.