Hello to all. Looking for some help. I have a 2005 200D with 3800 hours on it. I replaced the excitier brushes at 1000 hours. One was wore more than the other. I had no problems during the time up until now. I started getting a few very small pinholes on the egde of my caps. Not on every cap here and there. I am welding 12" and 16" .375 and .500 wall X52. Capping with 3/16 HYP+. THe inspector is pretty easy and has no problems with just peening them shut. Provided they are not to big and that X-ray has no problems. There has been a few I have recapped. My caps are straight and uniform with no slipped ripples. So I do not believe it is my eyes they are working good. You do not see them to try and step back into them. Anyway I replaced the excitier brushes again hoping that maybe was the problem but I guess not. I stoned the main generator and checked the brushes I would say that the brush wear is more than 3/8 but less than a 1/2 from the pigtail. This started before Christmas. I was hoping it may be the rods but I do not believe it is because my partner has not had a problem. He also has a 200D with only 450 hours on it. I hoping maybe sombody may know somthing or maybe Kaye my read this and have some answers. I bought the new excitier and generator brushes from her. Well I am hoping sombody may have a few answers that may have had the same problem with a 200D or just a 200. I posted it here hoping more people will read it here than in the SA-200 section. Looking for some good answers and not that I should have bought a Vantage. Thank you everybody for your time. 583H