New guy with some questions...

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I have never welded before and have started on the path of learning.  I signed up for a week of MIG instruction at the Lincoln Welding School in CLE. I have a website and have invented a couple of things that I sell on my site along with my other products.  I have some new ideas of things I would like to make and sell.  When I went to the fabrication shop that would take such a job, he quoted me $600 for one and the price would go down with more units.  This was about $350 more than I wanted to spend, so I figured that I could have him cut and bend the parts and weld it up myself, saving me the money in labor and acquiring a valuable skill that I could apply to tons of other projects I want to do.  My projects will consist of welding 12ga sheet metal to form a fairly simple box.  Other projects will be made of 1/4" mild steel.  I plan on welding quite a few of these, so duty cycle will be of some concern.  My question is on which welder to buy.  I have 220v in the garage.  I looked at the 180 size MIG welders and was told that they will do what I want, but the duty cycle is short (30%).  If I go up to the 215/210 size welders, I will gain some duty cycle but lose some adjustability from what I understand.  What I THINK I need is a 250/255 size welder that will easily weld 1/4" steel with a good duty cycle, and will also take care of my 12ga needs.  I'm looking to buy the right machine the first time to save money in the long run.  I know that this might be overkill for some, but because I am planning on doing some production work with them, I need the extra power.If anyone can set me straight, I'm all ears.  I'm in the market for a new or used welder and am looking to spend about $1200 max for it, which is a bit below the range of a 255 size welder.  I lean towards Red, but Blue and Yellow (ESAB) also appeal to me.Thanks in advance for the help.-Dave
Reply:I just spoke with a guy at a welding shop that said that the 215 would be adequate for my needs.  I learned that the voltage "Taps" as opposed to the "Continuous" controls mean less adjustability for the voltage, but I can adjust the wire feed speed to get exactly what I need.  Is this correct?  I think a 255 would be a little much for me as it is designed for professional use and all day welding - not to mention the cost. I guess I need to keep reading my Procedure Handbook of Arc Welding...Don't believe everything you think.
Reply:Originally Posted by Spooled-upI just spoke with a guy at a welding shop that said that the 215 would be adequate for my needs.  I learned that the voltage "Taps" as opposed to the "Continuous" controls mean less adjustability for the voltage, but I can adjust the wire feed speed to get exactly what I need.  Is this correct?  I think a 255 would be a little much for me as it is designed for professional use and all day welding - not to mention the cost. I guess I need to keep reading my Procedure Handbook of Arc Welding...
Reply:So for every work piece, there is also a correct voltage and wire feed speed?  IF this is the case, does this machine limit me compared to one that has infinite adjustability?Don't believe everything you think.
Reply:Hey Spooled-up,I'll add to what John(weldgault) said regarding settings for different welding parameters such as thickness variations. If you are going to weld thinner metals to thicker metals, thin to thin, and thick to thick, you will find an optimum heat/wire feed setting that will give you the best weld. I believe a 210/215A MIG unit would serve your needs quite adequately for what you intend to do. I do many combinations such as this and I found it simple to just do some test runs on some scrap combinations to establish your settings. Then make a simple combination chart to list each setting for that combo. Since I do production work on a daily basis, and am a Production Design Weldor, I find you will increase production by establishing a routine and if you have some knowledge, get/or make yourself some jigs & fixtures that will have your pieces precisely located for welding. You have to do a little homework to determine the best way to set up your assembly procedure so you can establish a method of efficiency. You can do it....think each process thru....it will become clear. Don't hesitate to query those here who can provide some valuable information. Good luck......   DennyComplete Welding/Machine/Fab. ShopMobile UnitFinally retired*Moderator*"A man's word is his honor...without honor there is nothing.""Words are like bullets.... Once they leave your muzzle, you cannot get them back."
Reply:Originally Posted by Spooled-upSo for every work piece, there is also a correct voltage and wire feed speed?  IF this is the case, does this machine limit me compared to one that has infinite adjustability?
Reply:The machine I'm referencing is the Lincoln 215 with 7 taps.  The output range is 30-250 amps and the wire feed speed is adjustable from 50-700 ipm.  If I divide up the the range into 7 settings I get 30, 67, 104, 141, 178, 215, and 250.  Does anyone make a MIG welder with a continuous adjustment in this size?Last edited by Spooled-up; 01-24-2008 at 03:48 PM.Don't believe everything you think.
Reply:Originally Posted by Spooled-upThe machine I'm referencing is the Lincoln 215 with 7 taps.  The output range is 30-250 knots and the wire feed speed is adjustable from 50-700 ipm.  If I divide up the the range into 7 settings I get 30, 67, 104, 141, 178, 215, and 250.  Does anyone make a MIG welder with a continuous adjustment in this size?
Reply:Thanks for the help John.  I'm thinking I may need to find a machine that is a little more adjustable, but the adjustability only comes with a larger machine.  Any opinions on ESAB welders?  They seem to be a little less expensive, but that may be because they're not the "big two".Don't believe everything you think.
Reply:Originally Posted by Spooled-upThanks for the help John.  I'm thinking I may need to find a machine that is a little more adjustable, but the adjustability only comes with a larger machine.  Any opinions on ESAB welders?  They seem to be a little less expensive, but that may be because they're not the "big two".