115V Arc/Stick for 1/8" angle iron...

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So I probably won't be doing much welding besides one project for my pickup bed which will probably be constructed almost entirely of 1/8"x1/8"x1" angle iron and maybe some other 1/8" stock.  I don't have any good 220V options without running a new circuit which doesn't seem worth it for what is likely to be a passing hobby.  So I'm left with 115V on a  20 amp breaker.  I realize this is far from optimal but I'm operating on the assumption that with such light material it should be OK and since it'll mostly be short 2" runs followed by fussing with jigging the duty cycle will be rather low as well.  And of course, I don't want to spend a lot of money .So, with all that in mind, a few questions to those of you with more experience:1. You think doing work on 1/8" material with such low power welders would be OK?  Any gotchas or recommendations?2. It seems like my options are fairly cheap AC units putting out at most 80 amps (Clarke comes to mind, the harbor frieght version looks really pathetic) or fairly cheap inverter based DC units (harbor freight has a 80 amp that might be passable).  Any thoughts on whether a straight AC or inverter DC is better for an el-cheapo 115V source?3. Any specific welder recommendations, keeping in mind I'm really just setting up for one project and not 20 years of shop work?4. Electrodes, it looked like 6013 was probably the best choice for low current.  Again, I'll mostly be doing butt joints with 1/8" material (unbeveled).  Good idea or is there something more appropriate?Anyway, I'd appreciate any advice anyone has got.  For what its worth I have oxy-acet experience but haven't done arc welding before so I'll probably be doing a fair bit of practicing first as well.Thanks!  Ken
Reply:Buy a 220 unit and plug in to your dryer plug and there will be no question.  If you must buy a 110 unit try to find someone that has one and try a few scraps to see how it goes.  Miller seems to be the best (do they make a 110 unit?) although each brand has it proponents.  Used buzz boxes seem to go pretty cheaply.  Welding is addictive, few of us get rid of welders unless it is to buy a bigger one.  Oxy/acet works fine too and there are other things you can do with it (heat wrench, cutting, etc).Thermal Arc 185 TigHTP 200 MigCraftsman O/A1942 Bridgeport Mill12 Ton Hyd PressConsew Walking Foot
Reply:I use a Thermal Dynamics Dragster 80.  It is a inverter.  I use it frequently in the field.  It does 1/8 inch well.  I run 6013 straight and 6011 reverse polarity.  I use 6011 most often.  It will not run rods larger than 3/32.  I have never had problems with the duty cycle.  I usually just leave the amps maxed out.It works well as a tig machine, though you do have to scratch start.  It tigs 1/8 inch at about 40-50 amps.  Tig weding would go well with your O/A background.  It much cheaper than O/A welding too.   I think 80 amps will do what you want.  Though practice much to make safe welds.  It is harder to use a small machine to make good welds than a large one with more amps.    As stated If you have access to a 220 dryer, then plug a 220 welder in there.  You will have to match the outlet with the plug or plug with outlet.  A/C 220 welders are cheap.  I got one for $25.  Though they can be found for under $100, frequently.
Reply:Originally Posted by kwalsh2. It seems like my options are fairly cheap AC units putting out at most 80 amps (Clarke comes to mind, the harbor frieght version looks really pathetic) or fairly cheap inverter based DC units (harbor freight has a 80 amp that might be passable).  Any thoughts on whether a straight AC or inverter DC is better for an el-cheapo 115V source?  Ken
Reply:What is the job you are doing Ken?If it's to hold down an extra 5 gallon gas tank vs holding down an extra large spare tire... it may influence the input here.Share the project purpose and the design.I only know one KWalsh in Tucson...... you must be him!***************************************Lincoln AC225 stick welderLincoln HD100 WeldPak flux core wire feed welderThree of the cheapest grinders money can buy
Reply:BTW, I thought I wouldn't do much welding beyond the one project I started with.... now I've done many projects and own two welders.The uses for a decent welder just never stop.  Just the other day I was tired of my wheelbarrow tire always being flat, so I purchased one of those solid-core rubber tires and wouldn'tyaknow the tire was just slightly too large?  So I used angle iron and elongated the front crossbar support that goes in front of the tire.I've welded my shop doors.Made a custom mobile chicken coop.Fixed shelving.Fixed a broken seat frame in my truck.Welded sides onto my utility trailer (angle iron and expanded metal).etc.... the list just keeps growing.I own a Lincoln flux-core welder, 100 amp, Home Depot $359 or so, and I own the AC225 Lincoln stick welder, $240 or so from Walmart.  I wanted the flux-core so I could weld outside without using a wind break and I didn't want to buy welding gas, and I have the AC225 stick machine for the big jobs.Just my two cents.***************************************Lincoln AC225 stick welderLincoln HD100 WeldPak flux core wire feed welderThree of the cheapest grinders money can buy
Reply:Thanks for all the input everyone!KRS, the project is to put in what would essentially be a raised "floor" in the bed of my pickup for camping.  Usually the majority of my camping gear is in those plastic crates with attached folding lids but of course there are larger items as well (high lift jack, chairs, cots, stove, etc.) that are loose.  If I load everything just right it doesn't move around too much.  Then, if I want to sleep in the truck bed (it has a camper shell) I have a section of plywood I can flip on top of the crates and I don't have to move anything out.  It is a little awkward though.So the idea is using 1/8" angle iron to make a structure that supports removable plywood floor boards for easy access to things underneath, is mostly open underneath to allow those crates to slide in from the tailgate easily, and uses the floor supports to try to keep the larger items in place as well.  It would be a semi-permanent thing - probably made in three or four sections - that would be held in place in the bed with U-bolts attached to the strapdown hooks that line the top of the bed (these wouldn't be supporting weight though, just keeping the sections in place).When in motion the structure would only be supporting the plywood and any sort of shifting/sideloads applied to the supports by any camping items/crates trying to slide around.  At night it'd be supporting my and my wife's weight.So I think 1/8"x1" angle iron should be plenty strong for the task (I might beef up any corners that take a load) and if a weld fails I'll simply look inept as opossed to dead.Any thoughts?Thanks,  Ken
Reply:I definitely think that 1" angle iron (hot rolled) will be enough, particularly if you build two or three of them, and slide them together instead of one giant unit.  A larger unit would require longer spans and would require more support and it would get ungainly heavy.If there is a corner you are worried about, then "gusset" it with a small metal triangle welded in the corner.  I do it by purchasing a small piece of sheet metal and cut it into squares (4-5" squares), then cut the squares into triangles (two per square).I think you'll be fine with a small stick welder, but stick isn't the easiest to learn on.If you are who I think you are...... ?  I may try to schedule a saturday and come over the weld it with you if you have all the parts cut out and ready to go.  I could bring my 110v wire feed welder... it's much easier to learn on.  I'll have to look at my schedule and see.  If you drove your truck and the materials over here.... it would be much easier for me Do you have a plan already made up?PS.... I think overlapping joints would be better than butt joints with no overlap.  It will put your sides 1/8" in from the top or vice versa... but It'll be much stronger.***************************************Lincoln AC225 stick welderLincoln HD100 WeldPak flux core wire feed welderThree of the cheapest grinders money can buy