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TIG Welder Recommendations

C

Christopher S.

Member
Good Morning Gentlemen, we have a project coming up that will require modifying some underbody aluminum diamond plate tool boxes. I will need to add an extension to the back of these boxes (essentially making the boxes deeper). This will allow a set of aluminum ramps to be put into the box for storage.

Its been probably 12 years since I took a class and did a little TIG welding. I'm looking to you guys for any recommendation on a machine to look at purchasing. There are cheaper ways to tackle this project but I would like to add this piece of equipment to our shop and increase my skill set.

I would anticipate my needs for welding aluminum to not be all that frequent, so an all out production machine or super high duty cycle wouldn't be necessary. I couldn't see myself needing to use material over 1/4 thick. I was hesitant to go the ebay or harbor freight route thinking that replacement parts may be non existent a decade from now. Thanks for your input gentlemen.
 
How much money do you have to spend? 1/8 in aluminum requires approx 200 amps AC to weld. I have a Lincoln 225 Which will barely get you by. The duty cycle on these machines at 200 amps is so low that they overheat very quickly and shut down. I personally would never buy anything else that had less than 300 amps. If you are going to do much aluminum at all you need a water cooled torch also.
 
There is no guarantee that parts will be available for a Miller or Lincoln will be available in a decade either.
 
Do you need to TIG weld these boxes? ....Aluminum welding can also be done with a MIG welder and Spool Gun.
 
I built an 18 foot welded aluminum boat using only my Lincoln SP 170T Mig. 1/8 and 3/16 plate. I fought a few birdsnests, but never enough to go to a spool gun. Using 5000 series wire helps, because it is stiffer than 4000 series (and more corrosion resistant). After 20 years it is still staying on top of the water, in spite of dropping a tree on it a few years ago.


cvphoto114690.jpg
 
Spool Gun will make the task reasonable and easy to learn. MIG has a learning curve about 1/4 of TIG time, and better position results.
Power supply is separate (as are TIG setups) Jim
one example
 
I just could not imagine running a our foot long TIG bead down a huge tool box. Then three more sides yet still to go
 
(quoted from post at 05:39:40 01/20/22) Good Morning Gentlemen, we have a project coming up that will require modifying some underbody aluminum diamond plate tool boxes. I will need to add an extension to the back of these boxes (essentially making the boxes deeper). This will allow a set of aluminum ramps to be put into the box for storage.

Its been probably 12 years since I took a class and did a little TIG welding. I'm looking to you guys for any recommendation on a machine to look at purchasing. There are cheaper ways to tackle this project but I would like to add this piece of equipment to our shop and increase my skill set.

I would anticipate my needs for welding aluminum to not be all that frequent, so an all out production machine or super high duty cycle wouldn't be necessary. I couldn't see myself needing to use material over 1/4 thick. I was hesitant to go the ebay or harbor freight route thinking that replacement parts may be non existent a decade from now. Thanks for your input gentlemen.
Click to expand...

Dirty aluminum. Won't be fun to weld. As said, 300A or greater. I wasted $2K on a 180A Lincoln TIG a few years ago. The board just burned out at 2/3rds the cost of new. Don't waste your money on toys or just enough machine. It's cheaper to buy twice the machine you think you will need. Your TIG choices are 350A Miller or Lincoln machines. If you want a MIG, take a look at HTP. Light years ahead of Miller's 350P Aluminum. We've been using one for a few months to rebuild a wrecked pneumatic and assorted truck repairs and it outdid it's reputation. Last thing the boys built was ramps for the lowbed out of 3/8" 5000 series. Going to test them for cracks with 87,000lbs loaded over the back.
 
Suggest ,hire it out, if not used weekly ,then its one more thing to store.
Or can you use the one you took the class from ,I think my community college here will let me use theirs .
Anyways just a suggestion .
 

Many years ago I wanted a MIG welder, I looked at both a 120v and 240v Lincoln, I bought the 120v thinking that if I needed reach a long ways I good just use a heavy 120v extension cord, rather than needing 240v receptacles and 240v extension cord.
Well the 120v MIG draws about 22 amps when turned all the way up, and yes I need it turned all the way up at times.
 
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