Filler Rod Size

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It's been a while since I have posted here, but have been following the posts.I am now working on TIG welding and I was wondering what is the proper size filler for lets say 1/8" mild steel?  The guy at the welding store said, "well if you going to be welding 1/8" material, then you need an 1/8" filler rod".  Well the chart for the welder indicates to use a 1/16" filer rod.  I called Lincoln and they confirmed.I just wanted to hear some some other people opinions if it is possible to use a filler that that is slightly larger and still get away with a good weld, and if so, is the technique any different?  e.g. more heat, slower travel etc?I would like to ask the same question for Aluminum welding also.I am using a Lincoln Precision TIG 225.Thanks!MikeBuild a Barstool Racer at BarFlyRacers.com!
Reply:i use 3/32 on both metals.
Reply:1/8 filler is huge to me, normally I use .035 and 1/16.  Only time I go bigger is for thick  AL work or filling gaps.Definatly dont need 1/8 filler for 1/8 material, I wouldnt even use it for 1/4.  Granted you use more filler if its thinner, and you have to feed it more but I have alot better puddle control that way.Have we all gone mad?
Reply:I'd go with 1/16"..Gives you a better chance at real penetration.....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:Ok, sounds good.  I got some 3/32 and 1/16 filler rods for Alum. and Steel today.  I also picked up a 1/16 red tungsten to test with.Thanks for the help!Build a Barstool Racer at BarFlyRacers.com!
Reply:For 1/8, 1/16 filler rod, unless all you have on hand is 3/32. 1/8 TIG filler requires a bigger puddle than you want to try to maintain on 1/8 material.
Reply:1/16" for SS and mild, I have 1/16 and 3/32 for Al.Disclaimer; "I am just an a$$hole welder, don't take it personally ."
Reply:Always run the smallest you can get away with.As a rule of thumb, you never want to run filler rod that is any bigger than the material you're welding on.
Reply:Originally Posted by SupeAlways run the smallest you can get away with.As a rule of thumb, you never want to run filler rod that is any bigger than the material you're welding on.
Reply:Originally Posted by enlpckUnfortunately, you sometime you gotta go bigger. See my post in the pics forum. ("entertain yourself" thread)