What do i need?

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I would like to start welding some aluminum, with thickness under 3/8".  Steel fab would be about the same thickness.  I am thinking that TIG is the way to go.  My current equipment are all 110V,  Lincoln Mig Pak 10, and a Blue Point Plasma cutter.  If there was a combo unit that could TIG and Plasma cut, it would be a bonus.  I have 220V right in the garage.  Used is ok with me....just need some suggestions for the right units to look at under $1500.  Also, some suggestions on some better books on TIG, working with aluminum(tube bending, fab, etc..) would help.  I have one book, but it is very broad, so it doesn't go into a ton of detail on the processes.  Since I am a relative outsider to some of the terms of welding it may help to have specs on machines that could handle the requirements I have rather than the machine model itself(although that's welcome too!).  Example.  You need at least 150A, water cooled, 220V and reccomend one with a Snitzel popper because of X.  LOL,  I just don't know the questions to ask...Thanks,  ChadLast edited by chadtoolio; 05-04-2009 at 08:38 AM.Reason: Ignorance
Reply:The first thing you might want to do is a search on here, use the search feature above and just type in a general search for aluminum welding and it will come up with a ton of threads on the subject, then read and devour as much as you can on the subject!#1. If you don't like what I wrote, or if it offends you, then don't read it!#2. I am living life the way I see fit, if you don't like the way I'M living, tough sh**!
Reply:I am by no means an expert, but I definitely dig my "Miller Diversion 165".  I just finished messing around with some 1/8" and 3/16" pieces of ALUMINUM out in the shop and I LOVE THIS THING !I can't believe how EASY it is to weld aluminum now !  TIG is definitely the only way to go when it comes to this type of welding.  You'll be able to pick this unit up NEW for the price you are looking at and that would likely include the foot pedal as well, although the built in finger controls are pretty nice when laying on your back under a car or something...Check out some of the LWS's and see if they can DEMO one for you, I think you'll be VERY impressed at what this machine can do !***NOTE:  You CANNOT do stick with this machine unless you use the 'TIG TORCH' as the rod holder.  That's the trade-off for the price of the machine but IMO it's not a big deal as I can buy a GREAT used stick machine for a few hundred bucks.***Cheers,/Jman...
Reply:Really?3/8" AluminumTig/Plasma ComboUnder $1,500I would suggest that you go to the Miller site (millerwelds) and look under the Resources tab.  I'd recommend ordering their "Student Pack" for $25 (shipping included).  This will include an excellent Tig Handbook along with a lot of other cool material.Once you've read the book, you'll better understand why your original question was so "far out".The only thing that even comes close to what you described are some of the Chinese Junk Machines, which I wouldn't recommend, even for a boat anchor.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:Originally Posted by chadtoolioI would like to start welding some aluminum, with thickness under 3/8".  Steel fab would be about the same thickness. Thanks,  Chad
Reply:Don't just jump on the first bandwagon (Dealer or Salesman) that rolls by you. First determine what your existing needs are and try to predict your future needs as well. It always better to go with slightly bigger than what you currently need! That way your prepare for the future.Do your research! DO YOUR RESEARCH!! There are plenty of experienced folks here with loads of experience and equipment and Internet sites such as Miller, Lincoln and few others have plenty of good information that can aid you in your search.If your going to be using it for daily or business use do not try to slide by on the cheap because you'll later regret it.Co-Own CNC shop:Miller :1251 plasma cutter, MaxStar 700 TIG/Stick, & XMT 456 Multiprocess Welder.&  2 Hypertherm HPR260's Plasma CutterSorry I had a bad stroke but now I am back.
Reply:I just LOVE posters making recommendations about equipment/welders, when they don't have a clue about what they're talking about.Maybe someone else should also order the Tig Handbook.  Some basics of tig welding were obviously not covered in the "Tig Welding for Dummies" manual provided.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:You can tig 3/8" aluminum with a small machine if you prep the joint in a v-groove and weld it in multiple passes.  Expect to pay $2000 and up for a descent ac/dc tig machine with torch, pedal and cables.  Expect to pay another $1000 and up for a descent plasma cutter, and no, you're not going to get a good tig/plasma all in one machine.   Tig/stick yes, tig/plasma, no.Since you're on a budget, I recommend you search Craig's List for used machines.  Hypertherm 380, Miller Spectrum 375 and Thermal Dynamics 38 are all good entry level plasma cutters.   You will also need a good air compressor to go along with it, one that has a high air delivery rating.  Look for a cfm rating of 10 or more.If you have alot of amps of 220v power available (by alot I mean 100 amps), then an older ac/dc transformer tig machine would be the cheapest way to go.  An old Dialarc HF, Syncrowave, Idealarc 300, etc. is what I would look for.   If you don't have big power available (50 amps or less), then you'll be looking for an inverter and spending more money.  The Thermal Arc 185 and Dynasty 200 are both great machines.   HTP has the Invertec that is also a good one to look at.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:I wouldn't trust the weld made in 3/8" aluminum with a Diversion 165, I don't care how it's v-grooved, preheated, and made with multiple passes.One of the first things I was taught in marine aluminum fabrication was that multiple (double) pass welds were to be avoided like the plague.  Double pass in aluminum adversely affects the HAZ and often leads to failure of the joint just adjacent to the weld bead.  I've personally seen this occur on way to many occasions for it to be "just an old wives tale".Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:wrong post.
Reply:i may be wrong but would this fellow be better off trying to find a used mig whith spool gun option for aluminum
Reply:I think you might be right fisherman, but it will still need to be a pretty hefty machine for 3/8 inch stuff. I used to use a 400 amp Dialarc HF and 3/8 was pushing on it pretty hard. Gonna be hard to find even a used tig with that power for 1500.00 unless it is ancient.The difference between art and craft is the quality of the workmanship. I am an artist.
Reply:Miller made 400 amp Dialarc HF's ?  My Dialarc HF is only 250 amps on AC output, 310 amps on DC.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op