mig .035 vs .045

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I'm going to weld 2.5" x 2.5" x .25" square tube, mostly T joints, using my millermatic 250x. I've got 75/25 gas. Should I use the .035" solid wire I've got or get some .045" ? Any other suggestions?Ian TannerKawasaki KX450 and many other fine tools
Reply:Go for the .045 wire, although either will do it. If it is a small run then just use whatever you normally use. I just finished up  a large project welding a lot of 1/2" bar stock and found .045 to give much better results and faster deposition than .035. I now keep spools of both in the shop. In fact I am keeping .023, .035, and .045 on three different welders, so I don't have to swap spools, just turn on a different machine.
Reply:BTW, my LWS can get Lincoln .045 in 11 pound spools. I bought one to try out before buying a 33 pounder.
Reply:035Your going to have a big "gap" to fill with the radius of the tube.
Reply:.045 with 100% CO2 is what I run, it flows in great on heavy sections, and it is cheap.Disclaimer; "I am just an a$$hole welder, don't take it personally ."