[seanc]

Adam:

The largest thing I have tried to plate so far was no more than 4 sq in(big M20 x 30mm bolt).

This may be the problem for a couple of reasons:

1. at 140mA/sq-in, you're only after 560mA total (.56 amp). From the photo of the rectifier, it looks like the amp meter resolution is @ 1 amp. The pictures not real clear, so it's hard to determine the graduations, but you get the idea. The amp meter will barely be deflecting.
2. at very low resistance values, some power supplies won't even activate. What does the documentation say about minimum load? Minimum voltage? Minimum current?

Fun thing is that I have to set the voltage using the dial and voltmeter before completing the circuit, or I get nothing. Once the circuit is completed, the voltmeter shows the voltage drop across the circuit, and the ammeter moves slightly above 0. Not sure what this is supposed to indicate. Attempting to adjust the voltage dial once the circuit has been completed does nothing.

That's how power supplies that don't like low resistance loads behave. You may have one of them.

The effective resistance of the electrolytic cell (anode/electrolyte/cathode) is quite low, sometimes less than .5 ohm (depending on all the variable factors). Many low-cost power supplies just will not drive that kind of load, the protection circuits cut in.

The workaround is to wire a low value resistor in series with the positive lead. That gives the PS enough load to operate. It will also let you measure current more accurately. Measure the voltage across the resistor, and do the math to calculate current.

That's why 1 ohm is a great value: voltage across 1 ohm = current. You'll be able to set low currents more accurately than your meter permits.

And having that resistor will allow you to confirm proper operation in the first place.

The primary issue is that I have no idea what's actually going on since both gauges are reading < 1 amp or volt

for parts that small, both voltage and current will be less than 1. even much larger parts will rarely get above 2 volts.

and no way of determining what voltage should be applied to being with.

Again, you don't care what the voltage is, only the current. I don't even have a working volt meter on my PS, it's broken. Set the current, and the voltage will follow, settling in at whatever it needs to be to provide the current.

Not having the ability to vary the voltage once plating starts is also a pain.

Since that's your only adjustment, it is a problem.

You really need to figure out whether the PS is functioning or not. Get that resistor & test it. If it works as expected w/the resistor, leave it in permanently.

I can't be the only one who has come up against this.

You're not. Most of the low-cost offshore CC/CV power supplies have the same problem. The resistor is the workaround.

Sean