Regrets..Regrets...Regrets....

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OK,  I've already slapped myself but I sold my HTP Invertig 201 and bought a Millermatic 251 because I was doing a lot more fab stuff with steel and my TIG skills were lacking on the thick stuff.  Now I have some aluminum that I want to work with and I no longer have the TIG unit.  I am thinking about re-investing again so that I can do some Aluminum and wanted everyone's thoughts on whether to go with a Spoolmatic 30A gun on my MM251 or just buy a smaller TIG welder.  I don't want to spend more than $800 to $900 bucks just because the wife will have a fit.  I know I liked my inverter TIG while I had it, its just that I have no knowledge of the Spoolmatic guns and how well they work.  I can see doing 80-85% steel and the rest aluminum.  Any thoughts would be appreciated.Michael
Reply:Michael, I had good results with a spoolgun on my miller 175. I wished it was pulsed... I tried a pulsed mig, and it was amazing. I like the mig, it's SO much faster. I could not imagine finding an AC tig welder for $800 very easily. I liked the way it worked, but the welds never did come out looking really good. Well, good, and strong, but not great looking. It was just a practice thing.And then, after so much work...... you have it in your hand, and you look over to your side...... and the runner has run off. Leaving you holding the prize, wondering when the runner will return.
Reply:I would imagine you could get away pretty cheap with a A/C buzz box and a HF box.  The HF would cost more than the welder. I think I would try spoolgun, however.
Reply:Hmm, that's a tough call.A used Econotig or Syncrowave might be had for what you want to spend.What sort of aluminum stuff do you see yourself working on?I see two ways of looking at it.  For right now, if your business could use a spool gun, buy it and it will pay for itself.  Down the road if you start having to turn away TIG projects, buy the TIG and it will pay for itself then.On the other hand, if you want to bite the bullet once, the TIG is more versatile.  Aluminum sure, but also stainless, intricate assemblies, small parts, "difficult" welds, appearance items, . . . etc.Favorite right now is a Miller Syncro 200.Tons of tools and I blame at least one of them when things don't go right.
Reply:You violated the #1 wife/tool rule - never admit you could do without something you already have; only mention the new tools you need.I'm just kidding of course, I sold my little mig after buying my htp201, sometimes I think for the few hundred bucks I should have just held onto it. - John
Reply:You didn't provide enough information.  What thicknesses of aluminum do you need the capability to weld?  That makes all the difference.  The spoolgun can usually weld as thin as only 14-ga.  It will excell at 10-ga. and thicker.
Reply:MAC it's kind of all over the place.  I'm making some tooling assemblies where the bases are 1 inch thick 6061 plate that forms a box frame for holding some shafts and bearings.  I also have some thin stuff around 1/8 that is needed to close in some frames that house the shafts (side panels etc.)My concern is some of the horror stories I've heard about feeding problems and penetration.  Now, my TIG skills were not the best but I could lay a bead and had good penetration which I believe is must.  I'd take a good solid weld over a pretty weld anyday (I know Zap gets both) but I'm not there yet.I don't expect appearance to be a problem however the welds need to be strong on the plate and decent on the panels.  I wish I could see one in use to get a feel for what to expect.Michael
Reply:You could find an old Dialarc HF or Idealarc TIG machine, if you have enough amps to run of those power hungry beasts, for under a grand and have enough amps to TIG the thick stuff as well as do the thinner stuff.   Look on craigs list or in the equipment trader, people are selling off those old beasts all the time.
Reply:on that thought of regrets....I turned down the purchase of an older dialarc because it did'nt have pulsing or HF start.  Anyway for 900 $  I feel I should have bought it.   Could have done a lot with it. weld it like you own it
Reply:If you have to work with thick aluminum it would be hard to find a reliable tig unit with enough amps to get you going...sure you could DC off an inverter with Helium, but think about the other aspect...speed!  The more work you can do at an acceptable quality level per unit time is what helps you make money.  Get the spool gun...make good welds and make a lot of coin then buy yourself a rocking TIG unit.
Reply:You know thats a sound point....I never thought it from that angle.Looks like Im shoping for a spool gun nowThe thick stuff I would rather go quicker w/ GMAW. weld it like you own it