I got a couple hundred of these to do. Welding 1/4"x2"x3" hss to 1/4" angle. I've been using only 1/8" rods for all 4 sides (2F 3F 4F) because thats what I've been told to do. I don't recall hearing of a procedure that calls for a 6mil weld in one pass in the vertical position. It works but turns out very convex and is more susceptible to undercut. Everything is galvanized so it needs to be grinded but I still run into it often which makes matters worse. I think 3/32" rods would do a better job in one pass but will take more time, however I feel would be worth it because all welds are to be inspected. What do you think?