You will be at the limit of the 100 amps with what your doing now. I had that issue in my first shop. IF many things where running in the shop you could tell the voltage drop when you would try to weld. Especially 7018 rods vertically. I had to shut off everything I could to make the welder work correctly.
So if you think you ever will add more stuff drawing larger electric loads I would put in the second meter with a 200 amp service. As for the additional charge. A shop is not going to be "free" you will use more electric than you think if you weld much. If you file a schedule F or a business return having a second meter for the shop makes it much easier to deduct the electric cost for the shop. Even if not your shop should run you $30-50 each month. That is less than $2 a day. Not a BIG expense compared to may other things you get or use.
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Today's Featured Article - Restoration Story: 1929 McCormick-Deering 10-20 - by Randal Simmon. On July 4th 1998 my dad and I was sitting on the front porch when he said that he was going to sell his two 10-20's to a junk man. He said that the junk man was going to give him $500 for both of them but he hadn't received the money for them yet. So I went into the house and wrote him a check for $500 and bought them myself and said now they are mine. He had bought them about five years before thinking that he was going to restore them himself. After five years sitting in the barn, he changed h
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