Need some advice choosing the right equipment for the job

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My dad and I both know how to weld reasonably well.  Lately we've been talking about fencing our property (about 5 acres).  We have a few welders, but running an extension cord obviously isn't practical.  So we'll be using stick welders to buzz together a fence, the details of which have not yet been worked out.  Our time frame is to maybe design and break ground on a project like this sometime around this summer.    The plan was to acquire a good generator/stick welder.  Specifically, a Miller BlueStar 185.But I've been looking at buying an inverter for myself, and specifically a Miller Maxstar 150.  It seems to have adequate power for our job.  It also costs less than the BlueStar.  The question is what kind of wattage generator would be required to run this welder?  We have two Robin generators - a 5500 watt diesel and a 6500 watt gas engine unit.  So for our application, the inverter might make more sense, if our existing generator(s) can power an inverter about the size of that Maxstar 150.So, what do you think?  Experienced input is appreciated.Also, any general advice for building a fence and fitting pipes is appreciated.  I ran some practice arcs today, cutting and butting pipes together and against flat plate (about 3/16" wall thickness stuff).  It's still a bit tricky for me, but I think with a bit more practice I can do it.  Any advice is welcome.
Reply:I would almost double the input for a welder when looking at a generator (always look at RMS output not peak output) that works for smaller welders for larger maybe try to get an extra kilowatt or two for cushion.
Reply:I have a 150s.  I power it off a honda 5000 watt generator,  that is 4500 continous.  I run off 220.  Have no problems running welder and grinder at the same time.  I rarely have need for more than 100 amps.  My generator will run the 150 at max amps, though rpms do decrease significantly.  I also, use a inverter off my truck for and tools.  It keeps things quiet and conserves gas.You really need to work on your overhead welding on round stock to prepare for your fence job.You will probably need to make a straightening jig to keep/get warpage out of the top pipe.
Reply:I have been using a Dynasty200 which is an inverter machine and a 6500 watt generator for fence work and have had no problems.  I weld at around 100 amps.  This setup works better for me than a generator/welder because I have to work in places where I could get the larger/heavier machine but it is no problem with the small inverter.  Be sure to use a sufficiently large extension cord if you have to use the welder any distance from the generator.
Reply:OK thanks for the advice so far.  My dad and I both being alike and both being toolaholics are now looking at various inverter setups that we might buy anyway.    I'll keep the other suggestions in mind.  I have been trying to weld different positions.  I made a few test butt joints between two pipes as I mentioned above, welding about 70 amps DCEP with 3/32 e6011 rod.  Had a few sticking issues welding uphill around the pipe, but that's a combination of my relatively low amperage and being mostly used to welding in flat and downhill positions.  The joints were still strong enough to withstand the beating of a 4 lb sledge.
Reply:A few years ago I built 1500' for pasture 2" pipe 2 rail fence at my folks place. I built "F" shaped sections just outside of the shop where I used my mig. Then when I had plenty, I brought them out and put them in place and welded the sections together. This way half of the welds where made easy and efficient. Also I made a jig out of C Chanel, that I was able to just place the metal in, and I would have uniform pieces. http://www.weldingweb.com/vbb/showthread.php?t=8037As far as your generator 6500 watt should run it.
Reply:depending on how long you think you will be using it for (maybe get a buddy or two to help and speed up the process), it may be more economical to rent a generator and/or welder. i think you said that you plan on using stick on it. if it were me, i'd use MIG or flux core... my flux core works great... especially on slightly rusty/dirty metal. the slag and spatter is a PITA, but it works great. my LE 100HD was only about 35-400 from Home Depot, not including any extras, which i woudl assume you already have (gloves, helmet, etc.). the wire is a little pricy (about 40 bucks for 10 lbs, but it works fine for me. it has never flipped a 25 Amp, 120 V breaker at max output settings, so i bet it woudl be fine on your generators. plus, then you wouldn't have to worry about running a bunch of rods... jsut grab a few 10 lb spools and go. it'll do up to 3/16" pretty well on a single pass... anything more is kinda pushing it. just something to think about.Later,Andy
Reply:Flux cored wire feed is something we thought about.  We can budget about 2 grand for a new welder, depending on how the next few months go financially with our present business, and buying a new welder is always exciting...    What about welding in awkward and upside down positions?  I was under the impression that most, if not all wires available were only suited for flat and downhill welding, but again, I could be very wrong.  Any thoughts on this?
Reply:with awkward (spelling?) positions, flux core works fine in my experience. when the self-shielding flux core wire is burned, the flux *(or something else in the core of he wire) vaporizes and creates the inert gas(es) right at the arc, similar as to if you had the nozzle inside the wore, rather than coming out of a cup/nozzle (i don't know the exact terminology). yes, this flux-cored gas does fall to the ground, as it is heavier than air, but since there is constantly a new bit of wire comming, with another load of flux, it is not an issue. plus, the flux tends to clean the metal pretty well. don;t get me wrong... it is not wise to weld with it in the mud, but if you have an extra bit of paint or what-not over the weld path, the flux will eat it up and spit it out as slag on the top of the puddle. Ask Tozzi and David R. they use NR211-MP on a regular basis... that's LE's self-shielding flux core. i know David R just used it on a trailer project with 10 & 11 ga plate gussets... 1/16" wire i believe. looks great... that's what my LE 100HD came with. the only reall issue that i have found with it is excessive spatter leads to increased clean-up time if appearance is a concern. other than that, it makes you more portable since you don't have to carry around gas tanks, and a 10 lb spool will last a while. hope that helps.Later,Andy
Reply:Ok flux cored wire is just like rods only inside out. The flux melts and forms a skin over the weld to keep the air out. As for the welder I have a Maxstar 150STH and a cheep colman generator 5500watt continuas. If you run it on 220 is will run all day with power to spare. You can also get a stick only version (150S) for abour $600 an awsom unit. Steel Thunder Welding LLC. St. Thomas VI USAMM350PBOBCAT 3MAXSTAR 150 STH375 EXTREME PLASMA6.5 HP COMPRESORDEWALT 18, 24, AND 36 VOLTO/A TORCH SETAND SO MUCH MORE I DONT REMEMBERALL IN MY 2005 2500HD EXTENDED CAB L/B
Reply:I run nr211mp thru a ln25 box and it works great in all positions and have seen it run in really crappy wx. I run 5/64's wire cause thats what I have. Built a 56' boat with it 15 years ago and boat still floats....
Reply:Originally Posted by CDG...we'll be using stick welders to buzz together a fence......the details of which have not yet been worked out...  Also, any general advice for building a fence and fitting pipes is appreciated.
Reply:We are primarily interested in building a rail style fence, so probably we'll be joining pipes.  As for materials, we had a demo on a pipe driving mechanism for our Kubota tractor.  We're not sure we're going to use it or not, but if we do, we'll be looking at steel pipe with a wall thickness of approximately 3/16" and an outer diameter of 2.5 or 3".  It is not necesarily practical to set every post into concrete, as the soil where we live is particularly difficult to dig or even drill.As for the wirefeed versus stick, I think the jury is still out on that as far as our decision goes.  I enjoy welding stick, but I think better time could be made with wirefeed.  Since I am the best welder in our family, I think you can guess who will likely have to spend the most time out in the desert sun welding...    Which suites me because I don't like grinding and prep work nearly as much.
Reply:Unless you are going to MIG, then I don't think flux core is going to save you any time over stick.  I think a good stick weld is easier to clean than a flux core weld.
Reply:MIG is a possibility, but there are two concerns we have.  The first is that our bottles are rather large and would be difficult to transport.  We will be probably using our Kubota RTV to carry equipment in, as it is small and accessible to practically every place on our property.  Securing a large bottle inside such a small vehicle might not be easy.  The other concern is one that I have not experienced.  I have heard that sometimes in windy areas the shield gas can blow away causing a contaminated and weaker weld.  Supposedly this is less of a concern with flux cored wire.
Reply:This is true your shielding gas will blow away even in the calest of days. One thing I have done in the past is run CO2 over flux core. It seems strong and never had a problem and it keeps the weld looking a lot better. I think a good stick is the way to go. Were I live it is always windy and MIG is usually not an option so very often when installing a hand rail I just stick weld it. If your fit up is good it can go fast just watch out for gaps that slows you down a lot. Steel Thunder Welding LLC. St. Thomas VI USAMM350PBOBCAT 3MAXSTAR 150 STH375 EXTREME PLASMA6.5 HP COMPRESORDEWALT 18, 24, AND 36 VOLTO/A TORCH SETAND SO MUCH MORE I DONT REMEMBERALL IN MY 2005 2500HD EXTENDED CAB L/B