Tig cup size???

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Okay guys I know that there is a reason for using smaller cups, like getting into smaller or tighter spots....Is there really a difference than a #4 to #8 besides inside diameter,and gas flow? When do you know it istime to go to a different cup? I've been using a #7 gas lens and have been doing fine with that, but thisafternoon I put on a #4 cup not a gas lens and it was a little different. Trying to do a filled weld and just a regular flat weld I had to up the gas to about 15-18, with gas lens i can stay about 12-15. Just practice on 3/32Material using 1/16 tung.and filler on mild steel. Is there a good time to use a gas lens or a regular cup?Can I use my gas lens all the time?    I am sorry about all of the questions all at once but after watching allthe videos on YouTube seeing all of the different cups I needed to try it out. I know you guys are the peopleto ask. But be gentle I've only been tiggin for a few months now, doing alot of practice and have been through a pound or two of steel and aluminum filler each and about 1500# of argon so iam practicing.           Thanks guys.          James
Reply:Depends what you're welding. Carbon steel doesn't need the gas coverage like stainless does. For pipe welding, you go with whatever cup fits the bevel and doesn't scrape on the previous weld pass. So you usually start with the smaller.. say a 4 or 5 for the root. Maybe the same for the hot pass. A 6 for the next fill, maybe a 7 if you need another fill and a 7 or 8 to cap. You can do the fill and cap with a 6 if that's your style. I like a bigger cup for the cap. I also always use my gas lens. I've got a few spares if I happen to clog it up.. I dislike the diffusers because the cup doesn't walk as smooth on pipe as it does with the gas lens. In my experience. Edit. I mean the different shaped cups don't walk as smooth as the bigger cups for the gas lens.
Reply:Thanks badnews I don't do any pipe welding of anykind just a few pieces of aluminum tubing on a plate to hold some tig rods on my table. Just doing corners,fillets and the normal welds that a beginner does, a #7 will be okay? I know that I need to extendthe tungsten when doing some fillets just to get the arc close enough to weld. I've heard that some guys only use one cup for pretty much all of their welding. I just wanted to know if there was a time that you would be better off using a certain cup for a certain type of weld. Most steel and aluminum doing basic welds " flat or vertical, fillets or laps" would be okay with my setup,     #7 gas lens?  What about using .40-1/8 tungsten and or welding thin or thick material?
Reply:99% of everything I do is with a #5 cup and 3/32" red end....Stainless..Cold Rolled..Hot Rolled..Aluminum..Don't matter because I am lazy....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:What zap said. Everyone I've seen who does fancy tig welding uses one cup for everything and 3/32 tungsten. Mostly thoriated but I've seen lathanated and ceriated used too. Also, the gas lens collet body is always used, so the bigger, tapered cups. When I've done tig on stainless plate or aluminum (God forbid I ever have to again) I used a #7 all the time. I would say use whatever feels comfortable and gives you good visibility. Nothing wrong with a 7, and nothing wrong with using the same one for everything. Unless, of course, you can't.
Reply:Thanks Zap and badness I appreciate the info. It's nice to find out what some of the better welders are using and what reasons.I will play around with a couple and see what works best for me for an all around setup.
Reply:When you get a case where the Tungsten needs to be extended to get into a tight area I like a larger CUP and Gas Lens  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock