New guy from Colorado

[ranchero]

Hi - a different Steve here - from central Colorado. I've been reading over forums for a few months now. I'm just about to order a TIG setup.
I have used a 110v mig setup for about 15 years building stuff for personal automotive use (engine swaps, brackets, protection, etc). I also have a 110v plasma cutter.

The work I envision going forward is using 1/4 steel and aluminum for skid plates/protection, interior builds (custom camper stuff) using 16g aluminum and stainless, gas and water tanks, etc. I'm doing this for myself and potentially for custom work for others.

I'm looking at a 200DX and 250EX. It seems at the moment the 200DX would fit the bill. The 250EX would give me the ability to do heavier stuff in the future, but I'm not sure if/when I might need it.

If I go with the 200dx, I might be able to afford a plasma cutter as well.

Anyway - nice to finally be able to post. You folks have been a wealth of information so far
Steve

[Kempy]

Steve
Welcome to the forum if you do not have to do a lot of plasma cutting I would go with the 250EX it is a nice machine and the 200DX is also. I welded for years not using a plasma cutter just oxygen/acetylene torch. Good look on the welder or both plasma cutter and welder you buy Everlast they makes a good product.

[Shaggy]

Hi Steve, welcome to the forum. Just got started myself.

I'll try to give some of my impressions of the 200DX once mine gets here. It's scheduled for delivery for Thursday the 27th. I was thinking of getting the PowerPlasma 50 in the future but, we'll see how this 200DX goes.

Steve

[ranchero]

Thanks Kempy and Steve. I've got a ton to learn. Kind of excited for a change of pace.

[everlastsupport]

I would go with a PP50 and 250EX myself, both are top shelf. Both will handle what you need and make you very happy. 200DX if the budget it tight, will still handle the 1/4" with no problem and you can always upgrade later if needed..

[m j mauer]

Welcome to the forum Steve, I would go with the 250EX.

[DaveBonds]

Hi, Steve. I'm in a similar boat. I live up in Lakewood, similar experience levels. I went to vocational school for auto body and had training in MIG and gas welding about 15 years ago and I've been messing around with welding, since. I recently bought the smaller Powertig 185 for doing what I'm going after on a slightly smaller range of metal, than you are, and after doing a lot of research, I discovered some info that may help you decide which welder to purchase on a budget.

If you are going to run beads on 1/4" aluminum, that will try any TIG on AC with 220. It takes a bit to get the higher amps to heat and break through the higher melting point (more than double the core) of the outer oxidation layer on the aluminum. Older aluminum has more oxidation and is questionable, as to it's weldability, so be sure to try and adhere to 6xxx 5xxx and 4xxx series aluminum for building. Newer pieces weld better. I would suggest using 6061 aluminum with a 4043 rod. 4043 is typically all you ever use, unless you want color match on 5 series or if you are anodizing, then a 5356 series rod has to be used, or the anodizing won't take.

Do some searching on google and youtube about aluminum welding. One of the most valuable pieces of info that I found that helped me decide to get the one I bought (which ended up being the smaller of the two) was that the use of Helium gas, mixed with 100% Argon, greatly increases the voltage/ amperage output of the welder, on the same amp and volt draw that comes into the welder. This is because Helium displaces oxygen better than Argon and is a hotter gas, so it allows the arc to create hotter plasma with the same or less amp draw. You will notice a night and day difference in weld speed, weld amp requirement for thickness of metal and overall weld cleanliness and quality, when using Helium on big pieces of aluminum.

I would also suggest getting a #6 and #8 lens with a piece of metal screen as a diffuser inside, to help shielding. If you outfit your welder for Helium, even 20% to 80% Argon, you will see worthwhile results. In my opinion, if you were to save the money on a 200DX and outfit your welder with two tanks, Argon can be used on essentially everything, most of the time, but the Helium mixed in to your liking, up to 80% Helium 20% Argon is there for anything at 1/8" or thicker on AC for Aluminum. It really does help increase the capacity of the welder, increase duty cycle and essentially takes the load off of the machine to produce greater voltage and amps at the metal.

I went with a half bottle (40 cubic feet) of Helium on the cart, next to a full bottle of Argon. Both tanks use the same regulator (use plumbing tape and a light amount of grease on the ball head to get a good seal) with a 1/4" T fitting and you're good to go. You can get trace amounts of mixing if you don't use residual valves, but I really think it's unnecessary, because it's after the regulators and you're talking 10-20CFH on a 1/4" line. Say you shut the Helium off and want all Argon for something else, you might get a little helium up front, but you're going to until it's purged, anyway.

I'm going to see how often a half bottle will go, for my needs. Should it increase, I can always trade up and cash the bottle in for a bigger one. It's not as cheap as Argon, but the idea of taking a load off of the welder and potentially increasing its lifespan and range for certain jobs is why I went with the extra tank.

Check out http://www.weldingtipsandtricks.com and check out his youtube channel. Jody has some very good info.