Heading toward AL, fishing for advice

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Let's start out by clarifying that I know enough to be dangerous and get a few things done but not enough to intelligently chase down answers to a few questions I have.  Most of my welding is one-off fabrication/repair for my own shop use in steel and stainless but I want to broaden abilities to aluminum or simply enhance the capability of the toys I already have.  Looks like the fabrication part of my business in AL and Stainless might also be increasing in the near future. Even increased, it'll still be here and there welding, not constant production kind of stuff.  Right now I have a POWCON 400 SMT which I've only used for TIG (SS) on a few jobs.  Bought it new years ago and it's been a great machine but is under-utilized.  I also have a millermatic 251 with the standard gun and an old 225 amp canox buzz box which is used mostly to hold the floor down.I was going to throw some money at a spool gun for the 251 so I could do some aluminum if needed but got to thinking about the POWCON and the overall picture.  I was hoping for some advice on where you would throw the money to get the best capabilities from my starting point.  I have heard that adding the pulser unit to the POWCON might open things up to AL assuming I can get a  spool gun that's compatible (but that's not clear from internet searches)  I don't have the foot pedal or any of the other goodies for the POWCON right now because I've never needed them for the stuff I generally do.  If you had my starting point, wanted to be able to do MIG on AL, simply wanted to enhance the capabilities/ease of use all around.....which direction would you head?  I'm even open to selling if the value plus the grand or so I was going to toss at the project anyway would boost things into the territory of great. So let's say...budget of $ 1000 to $ 1500 plus the existing equipment, and the welding skills/knowledge of a hack---where would you take it if you were in my shoes?
Reply:If it were me and my machines, I'd just pick up a used Spoolmatic 30A for the 251.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:I agree with Duane. Lowest entry cost, and with mig aluminum, long welds/ high deposition rates are a lot easier to achieve than by using tig.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 bought a spool gun recommended for my MM252. I haven't opened the box. I've used a lot of 330 Cubic foot tanks of argon in less than 2 years with TIG. Aluminum TIG is kind of a love/hate emotion for me. Thickness is important, but MIG has some shortcomings I can't overcome. I'm in love with the Dynasty 280DX. I'm not in love with distortion caused by heat!
Reply:POWcon machines are great, but repairs are difficult if not impossible. Arcon is the new Powcon.   Also there is a big difference between machines when it comes to running aluminum.    I have had a Spoolgun on a Miller 330abp, lincoln SP250 and now a Miller 350p with all its advanced features.  For a total Al novice, running the 30a is so mooch easier to get a good bead down compared to the other machines, I would say sell both and just get the right machine.  Buy once,, cry once.  If you need TIG, a machine that suits your need too.  This is a that is making you money, the extra expense will be forgotten in short order when the savings in production time and quality from the right machine for the job is paying it's rewards.    If you a hobby welder or welding was not a major part of your business, then i would say just buy a Spoolgun.      Also good deals cab be found used in your budgetTiger Sales:  AHP Distributor    www.tigersalesco.comAHP200x; AHP 160ST; MM350P,  Spoolmatic 30A; Everlast PowerTig 185; Thermal Dynamics 60i plasma.  For Sale:  Cobra Mig 250 w/ Push-pull gun.  Lincoln Wirematic 250
Reply:When I was warming up to the idea of buying an aluminum welder I approached an acquaintance I knew had bought an old used MIG and spool gun. The model now escapes me. In preparation I cut out five pieces of 16 gauge to make a small box, I cleaned with acetone, and a flap disc. I spent an afternoon, and welded my little box. It was disgraceful! He had built a truck body, it worked, but wasn't pretty. TIG is a process harder to learn, but better suited to thin stock, bad fit, it is more versatile.