Best tig welder for my new business?

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I am a marine contractor and retiring my pontoon barge. I am constructing an auger barge. I will be using naval grade plate steel 1/4 and 3/16. The barge will be 30' long so there is a considerable amount of welding to be done. Strength is of the utmost importance of course. Cost is also a factor. I will also use this machine for various maintenance applications. Fabricating various custom dock hardware will be anthor application. I am constructing aluminum docks from 1/4 to 1/8 6061-t6 and this will be another application I will be using this machine for. So being able to have attractive welds is important. Speed is also important since time is money. Which i don't have much off right now. I will install whatever power requirements needed for the right machine. What machines can anyone suggest for these applications. I guess I need a good all purpose machine. Any help is appreciated.
Reply:I feel ike I am very qualified to awnswer your questions.I have been a welder for 15 years and spent 11 years welding on marine applications in San Francisco Bay.I also have built a 30 foot steel ketch and a 36 foot steel sloop which i sailed and lived on for 12 years on san Francisco Bay.First to help you a couple clarifications would be needed.Location in the world.Fresh water or salt water enviroment.Do you have a shop or would you rent a yard and work outside.For the steel barge first i would buy plans for a barge.Look in National Fisherman magazine. That will be a direct hit for you.There are a lot of used Miller Dial arcs for sale. a 250 amp machine but you want DC and AC. very important as far as selection of welding electrodes.If you have more money you can use wire feed -MIG.For outdoors construction use FCAW.For indoors use GMAW.Find a CC-CV 250 amp power source or larger and then get a LN-25 wire feed with 4 rollers. Any steel fabrication shop that does heavy structural worl can show you the perfect set up.For wire feed you will need a CC-CV power scource,  like the steel BUT the wire feed needs to be push pull for aluminum. Cobramatic used to be the king that info changes all the time.But the best info will come from the marine fabricaters up in WashingtonThey can tell you what works. Also the people that build garbage trucks use 600 amp wire feed machines for heavy plate.There is one of those in Novato California.As far as marine railings and walkways, 5356 is more corrosion resistant.Most marinas buy walkways in a modular prebuilt section and have their yard crew to install them. You should really go look at those.Having a barge is helpful to work from.Pilings in marinas are usually pounded ito the mud down to bedrock NOt drilled.You will not be able to TIG oudoors with much success or speed.TIG is for smaller more intricate work. It would be a waste to buy a Miller or Lincoln syncrowave and use it for stick welding..Last edited by Donald Branscom; 06-17-2008 at 11:24 PM.
Reply:Thank you for such a detailed reply. I will answer some of your points. Welded your own steel sloop? Quite a feat! I am a sailor and liveaboard from the past. On a 41 Morgan in the Florida Keyes. I have 31 dufour sloop sitting on the hard waiting for a refit one day. Hurricane Frances boat. Need to make some money first.You stated "First to help you a couple clarifications would be needed". I will answer these one buy one for you. Location in the world?Fresh water or salt water enviroment?Tampa Bay area and salt water full time.__________________________________________ Do you have a shop or would you rent a yard and work outside?I will be building it under an overhead enclosure and humidity will be high. No direct rain but outside just the same.____________________________________________There are a lot of used Miller Dial arcs for sale. a 250 amp machine but you want DC and AC. very important as far as selection of welding electrodes.AC/DC is very important and is something I must have.__________________________________________________  _________________If you have more money you can use wire feed -MIG. I must have gas and aluminum capabilities. Gas shielded welding is what I need and wire feed is a must. The aluminium docks require many welds per sq ft. They require attractive welds and also municipal and county projects spec out the materials to be used down to the wire. 6061-t6 is common for floating docks. __________________________________________________Find a CC-CV 250 amp power source or larger and then get a LN-25 wire feed with 4 rollers. Any steel fabrication shop that does heavy structural worl can show you the perfect set up.My shop where I Build the barge will also be for aluminum and wood floating dock construction. My supplier may be able to help me with that. I am a small business and many days this small yard will be idle. One year maybe two I can add a machine. Need a good all around machine if I can find one. __________________________________________________  _________Aluminum and for TIG you will need a Constant Current power scource.For wier feed you will need aa CC-CV power scource and wire feed like the steel BUT the wire feed needs to be push pull for aluminum.Yes I agree. I understand I need push pull for the softer aluminum wire. Can I find a good machine to build my barge out of steel? Then set up for aluminum work but, also be able to use for my occasional steel requirements?__________________________________________________  ___________As far as marine railings and walkways 5356 is more corrosion resistant.6061-t6 is a better aluminum to weld? It is what is spec on municipal docks as far as I have heard. The ability to weld both types would be good and to do so with speed and strength.__________________________________________________  _____________Most marinas buy walkways in a modular prebuilt section and have their yard crew to install them.I am a marine construction contractor so marinas are my target customers. Yes! They buy them from guys like me! Here they accept bids from locals. I want to build those modular units and make money. One day I hope.__________________________________________________  ___________________Having a barge is helpful to work from.You are very right. Here is my barge but, is what I could afford to build at the time. It broke me into the business. This is another reason why I need a good welding machine capable of aluminum.  This barge is ok but not really good. Many things are breaking on this aluminum frame. I was able to build this myself on a limited budget. It is mostly mechanical stainless fastners. The 5000# crain is bolted through 3" u-chanell and also through a  6" I-beam that runs the length of the hull. Too much flex still. I need a real barge. __________________________________________________  _________________ Pilings in marinas are usually pounded ito the mud down to bedrock NOt drilled.Here we have limestone and it requires a rock auger to drill and install poles. Some areas one can water jet and then pound them in. Limestone just splinters the end of the pole or it rolls off. The drop hammer you see has been retired in favor of a pnuematic pile driver to drive into the drilled hole, mud or sand. Rock is a constant here for the most part. 10" butt piling 7' into rock,  or 10' into mud or sand. Sometimes the limestone can be very hard. My barge is not cutting it. __________________________________________________  _______________________What I need is a versatile welding machine that will build my steel barge and also build aluminium  docks. In a timely manner. Too be honest this business has takin my last dime. This is why I am seeking the advice of experts before I make such a large a purchase that is so critical to my survival and success in this business. Just a location other than my house and garage is a reach for me right now. I will be doing all the welding myself. Not because I want to but because I have to. I graduated from tech school a certified welder 26 years ago. I welded for one year but did not pursue it after that. I have a small mig ac welder and a dc stick welder. It was short work to get the hang of these machines again and be able to run flat, vertical and overhead welds. Also I have run critical welds and none have failed or cracked in any way.  The gas, push pull is another thing altogether and I understand this. It will take much more practice and study  than the stick or mig has takin no doubt. Just setting up the machine is going to be greek to me. I am sure of this. After I select my machine and begin practicing I will have a whole slew of questions to be sure. These are welds that if they feel people may die. Myself to be specific at this time and employees down the road. I will have my welds tested for my piece of mind.I hope I hear from you in reply to my answers to your questions. I really appreciate your time, advice and experience.
Reply:I would second a real thought toward a mig machine. Pulsed mig, 250A, you are good to go. Tig would be too slow for that application; pulsed mig with a push/pull gun will fly, and give great quality welds. Just pick a color, blue or red.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:Thank you for your reply.How can I avoid the weld splatter? mig without gas?
Reply:Thanks for the detailed response and the photo.It really helps me understand your goal.I would break this project down into two parts.First selecting the welding power scource,  then selecting the wire feed.I would contact Miller and Lincoln and tell them you are going to build a steel barge.See what advise they can give you. And if money is a big issue stick weld it with a Miller dial arc or other industrial grade AC/DC machine. That is the least expensive way to go.Make your own cleats and other items for the barge.Make sure what Coast Guard requirements are. Then let them (Miller, Lincoln) know that you would like to use that same power scource for aluminum at a later date.You will have to let them know the thickness of the largest part of the barge. A GOOD welding supply store may be able to give you this info.Make sure the sales person knows what they are talking about.To build the aluminum docks you will need a pipe bender,So first -get the barge plan. Get a good plan made for the type work you will be doing. You should not pay over $500. Probably a lot less. Especially if it is standard.Second - get the welding machine and other materials.Make sure the space you are going to build the barge at has some protection from the property owner raising the rent in the middle of the project. Very important. Clear agreements -no resentments.After the barge is built start getting the aluminum welding wire feed unit anda pipe bender.Thanks for that info about Florida soil, Very interesting.
Reply:Power source?
Reply:The aluminium docks for the most part are fabricated on a cutoff saw and composite decking. That being said aluminium diamond plate can also be an option. The barge plan is tough. The website you mentioned I was not able to find any plans at all. My supplier for dock materials can help me with that since he builds his own barges and we have become friends. I have picked his brain so much I hate to do it any more. He is getting tired of me asking him questions. He has not indicated this but I don't want to push it right now. I want to spend a few more grand with him on some dock material packages. he has done me enough favors. The rent deal no problem. I appreciate the advice. I need a store front and then a small yard. Many of these local. I may be able to find this for under 2000.00 a month long term. I have a very good lawyer.
Reply:I agree with the suggestions about a good shop machine.Here's my thoughts on the matter. In marine construction is the ability to go to the job important in the work you do? Some times it is, some times not for this sort of work. You might considder an engine drive, like a Trailblazer as your power source. You can run the same feeders suggested above on a machine like this and it will give you the ability to be portable. You can also run a spoolgun for alum with this, and even smaller steel projects. Tig, either AC or DC can be added later if you find the need.The engine drive also gives you portable power for running tools, plasma cutter, air arc and so on if you need.
Reply:The only portable welding I will need to do will be stick welding on my steel barge. The barge shown can be trailered to my shop. I have considered the portable option. I can rent a big generator on those rare occasins I need to.
Reply:HERE IS SOMETHING FOR YOU.http://www.marinepiledrivers.com/?gc...FSLOIgodB0p0WQ
Reply:Been there. I need to build the barge myself. It is a good link and I am talking to them about plans. I appreciate your help.