Choosing Welder for Mostly Aluminum

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I decided to get a mig welder for working on Aluminum 1" angle by 1/8" thickness. All the local welding supplies shops keep pointing me to the Millermatic 210 with spool gun. I was a little shock with the price of $1875 (on sale) and thought it was a overkill for the type of work I would be doing. At most I would be welding no more than 6" at a time and duty cycle is not that important to me (this is a hobby). I realize the spool gun adds a good part of that cost to it. But I still would need to buy the consumables yet(gas,tips wire). Do I really need something that size to do that type of work. All the on line dealers are not that much cheaper ($30 or so) They all pointed me to the spool gun no matter what welder I choosed. Any thoughts or idea.Dennis
Reply:for that kind of $$$$ i'd look into a used tig..there are good ones out there...just what i would do......zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:with tig ya dont have to change out spool/wire if you want to weld different metals . i have used mig and tig  i  suggest tig for alum.  but thats me  a tig welder  yep look for a used tig/stick an there ya go --can fix any thing but the crack-0-dawn
Reply:I agree with these guys.  For 750 to 1000 dollars, you can get a good used tig machine.  A dial arc or maybe a miller 330 a b/p.
Reply:The first thing I thought was TIG also and I'm not even a TIG welder.It may be possible, in a low pressure hobby situation, to weld aluminum with one of the 175 amp machines.   For what you want to do such a machine might be OK, not good not excellet but OK.     There would be qualifications to that also.    One would be the occasional birds nest.   Another would be the need to keep the hose/whip as straight as possible to prevent feed jams in the first place.    It should be noted that there are kits available online that supposedly makes Aluminum welding a little easier with standard MIG guns.   One company is: http://www.wirepropellant.com/.   I haven't tried their product so I can't comment on it.    What I can comment on is the reality that there is a product available which should indicate to you that Aluminum without a spool gun or push pull unit leaves a lot to be desired.   Interestingly they offer that their system can help with hard to feed wires beyond aluminum.There may be a potential of using the "wirepropellant" system with the 210 machine and doing away with the spool gun.    Might be the best compromise as it would have the capacity amp wise to do the job.    Further if you really don't like the hassle of the jams you get with aluminum you can add the spool gun later.    Spool guns are very expensive as you have found out, sometimes it makes more sense to suffer a bit waiting till you have cash to upgrade.The biggest problem with going with a 175 amp machine is that you really are very close to being to small to do the job current wise.    1/8" Aluminum will at the very least require 130 or more amps with a strong slant to the more side of things.   So from a hobbiest perspective you have to determine if you can put up with the duty cycle.    The other thing is the 175 amp machines are not offered with the extra features that a lot of people doing aluminum seem to like. In this instance I do believe the dealer was trying to sell you an optimal system for the describe task.   It is actually a bit of a surprise.    Frankly once you get into that price range I would seriously think about moving up in the range.    Better yet see a Lincoln dealer, as it could be argued that they have a better system for MIG especially in the larger machines.   In any event I would give your dealer an atta boy for not trying to sell you more than needed for the project.ThanksDave
Reply:I'd buy the biggest tig I could afford.
Reply:I think your dealers are steering you right.  A spoolgun is the proper way to GMAW aluminum, and that's a good process for that material.  The smaller Millermatics, etc. do not do aluminum as well as advertisers would like you to think they do.  The MM210 is the right way to do a spoolgun, unless you need even more power, which you don't.  It's also one of the best overall GMAW machines out there; you'll like it and wonder how you got along without it.  And with Gun-On-Demand, you just pull the trigger on the spoolgun for your aluminum, or grab the other gun and pull the trigger for steel.  Of course, you'll have to change the appropriate settings and be rigged with both gas cylinders...
Reply:The MM210 is the best second choice.  First choice for me would be my TA-185.  My MM172 is rapidly turning into a dust collector.  Tig is the most relaxed and enjoyable hobby welding you can do.  Lotsa fun working the puddle!Last edited by Tailshaft56; 04-27-2006 at 10:44 PM.DennisThermal Arc 185-TSWMillermatic Challenger 172VictorO/AAtlas Craftsman 12 by 24 LatheEsab PCM-875Wholesalem Tool Mill-Drill
Reply:Don't know what all you guys are "tigged" off about.  I have had great results using my Lincoln SP-135 mig to join two pieces of 1/8" aluminum.  The key though, is you need a oxy/fuel torch and a 550 degree crayon.  As long you preheat to where the crayon leaves a smokey black steak and are working in zero wind conditions you can lay down a bead that flows like solder.  As for strength and brittleness, I have run over several fillet joints with an 80,000 tractor/trailer and smashed two-sided butt joints with a 10 lb. sledge only to find the welds still in tact while the parent metal failed.  Not too bad for a 110 machine blowing straight argon, a $9 roll of Lincoln SuperGlaze .035, and a $56 Lincoln Aluminum Liner Kit (part# k663-s).
Reply:I too prefer the TIG - there is just something about tig welding that offers a higher degree of versatility.  You can use your TIG power supply to arc weld too.
Reply:Originally Posted by wingitI decided to get a mig welder for working on Aluminum 1" angle by 1/8" thickness. All the local welding supplies shops keep pointing me to the Millermatic 210 with spool gun. I was a little shock with the price of $1875 (on sale)
Reply:Mac - well stated and all are valid points - especially about answering the question posed in the first place.Scott