Mig/Flux machines and Capabilities

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Hello fellas hope you dont mind a few noob questions. I have a little 140 amp Clarke welder. Its has been a good little machine for what Ive used it for so far. It has both gas and gasless side to it. I normally use this machine for sheetmetal work and works fine on the gas side. However I have some thicker stuff I need done. Basically welding 16ga to 1/8th inch all mild steel. The problem is this won't weld that on the gas side of the machine. Looking on the door at the " Estimated Settings" for anything above about a 1/16th they recommend using the Flux side. Short of buying a new welder... Is flux that much hotter? Also can I obtain a clean solid weld with the flux? I do have flux wire .035 that came with the machine just curious as to why it would weld it with flux but not on the gasless side? Welding 1/16th on top of 1/8th inch mild steel.
Reply:I guess what Im really asking is even with Flux Core wire and settings. Is this machine powerful enough to weld 1/16th to 1/8th inch?
Reply:Rough rule of thumb is that you need 1Amp per 1/1000 of an inch.  So 1/8 being .125, you need at least that.  With duty cycle, positions etc. you want a bit more.Keep in mind that you need to maintain a minimal voltage while putting out those 130 Amps.  Depending on the shielding gas this could be an issue.  Flux core makes that easier on the machine.Keep in mind that all this comes at a price in duty cycle.  It is unclear what standards Clark uses but I believe they rate their machines at less than 10%.  See the manual.So, max out the machine, use bigger wire (feeds easier anyway) and see what the bead looks like.  Can it wet out at the toes?As for welding 1/16 to 1/8.  Depends on the joint.  You probably have enough power to melt the edge of the 1/8 in piece, but not in the middle.  So T-joint with 1/8 going on a flat piece of 1/16, might work, vice versa probably not.  After seeing a boat trailer come apart (the rollers were welded on with a 110V machine), the joints broke right next to the weld.... zero penetration.  Like the metal was stuck on with chewing gum.  I know the guy that welded it, always bragging how is 110Amp MIG is such a bargain.  His bargain nearly cost a couple $1000 boat.  Thankfully not a big boat, thankfully most of the welds were in compression.  The bad part is now there is lots of grinding and re-welding to do.  BTW, the weld joints were so cold, rust formed behind them...You really need to try a decent 230V machine with C25 or C20.  I sold my Miller 251 to a guy who had a Lincoln 135sp.  When he lifted the hood after testing the 251, he was grinning ear to ear.  I raised the price $200 right then and there and he still paid  (just kidding - about the price increase, not the smile).  I personally think the experience is night and day one a 230 machine vs. 110.  The Miller 251 has a particularly flat voltage curve.Con Fuse!Miller Dynasty 350Millermatic 350P-Spoolmatic 30AMiller Multimatic 200Hypertherm PowerMax 1000G3Miller Maxstar 200DX