I searched around and couldn't find a topic for this so here goes:

As sad as this may be I am a Welding Engineer with minimal Stick experience. That may be changing soon, because I recently picked up a 96 XJ with a couple holes in the floor. Along with wanting to reinforce the unibody rails, this leaves me in preparation to purchase a welder to use at home.

I'd love to purchase a nice multi-use MIG/TIG/Stick unit, but don't have the extra $2-5k to drop on a unit. Honestly, I'd like to keep it under $500. Beyond the previously mentioned examples this will become a hobby welder.

The Lincoln AC 225 seems right up the cheap, easy, and versatile alley. However, as mentioned before I have minimal stick experience. I've used a generator welder to lay down some farm repairs on thick steel a couple dozen times, but never anything thin. I've Mig welded almost anything and everything under the sun. So, my question is, Who's done some autobody repair that could point me in the right direction?

 

mig.
the most popular seems to be the hobart handler.

i have a genny welder lincoln ranger but rarely touch the jeep with it. i've used it to fab up a couple bumpers in the past only cause i didn't have the power or plug adapter to use my thermal arc 210 mig fabricator.

i also have a lincoln precision tig but haven't really used it much.

my little 110 lincoln 140c gets lots of use on small stuff tho, but haven't tried it on anything structural.

same as my little inverter stick. used lots on smaller, hobby projects but nothing fancy.

the only problem with sticking to your 500 dollar budget would be the purchasing of a bottle. i own mine but used to lease them and they still put you out about 300 up front.

your best bet is to keep an eye open on craigslist for a decent slightly used model.

mig 180 for the win.

 

^What he said...

Stick with mig, get the best unit you can afford. Your price point of $500 will be tough, like caged said, the bottle alone is expensive, refills aren't, and you also need to remember consumables and gear, that will cost, too. I HIGHLY suggest you save some money and do it right though. I've used lower end (HF) welders, and wish I would have just saved my time and money, just got a Miller 211 with a bottle, and a cart, extra spools of wire and tips, for $900 on CL.

Avoid using stick anywhere near your body/panels, unless you like burning holes in things, LOL

 

I'm in an AWS welding course doing mostly stick welding on heavy plate. I can't imagine trying to weld much of anything on the Jeep with stick. You'd just burn holes everywhere you tried to lay down a bead.

Oh, there's definitely a topic for this. It's on the fabrication board:

Welding thread!!!!

It's now up to 74 pages. Careful what you wish for.

 

Thermal arc now tweco fabricator series really work well. I have the 252. It's a multi process inverter machine. DC only though. Haven't used TIG, but the MIG and stick is great. They come in 141, 181, 211? & 252 amp versions. Welding supplies @ Indiana oxygen supply has the best prices I've found (on anything) , and free shipping.

 

MIG is the most versatile and easiest, stick is great for emergency trail side repairs on suspension and frames.

 

Mig with 100% CO2.
Low cost and better penetration.

 

If you need to stay under $500 check out a welder/generator/pump repair shop. I got a Hobart Handler and a Miller from one. The Miller was almost brand new and the Hobart was older and missing the side door. I sold the Miller on CL for what I paid for both of them plus a spool of wire. I paid a little over $400 for both, that will leave a little $ for a bottle. If people don't pick up their equipment these places usually sell them for what they have in them (parts and labor).

 

Look at Tweco. They sell a 3 in 1. MIG/TIG/ARC. They are reasonably priced near your price range. You can get them in 140,180,210 amp.

 

Mig on CO2
Lincoln 180 at 220V
.023 on light gauge sheet, .035 wire on heavier structures
No worries
Wear a good helmet for UV eye protection, Jackson autoshade can be had for under 100 bucks
No OCChopper brainless Pauly BS welding without a helmet.
Wear a leather glove to protect from burns
If your doing a bigger weld job, arms and body need sheilding, UV will go right thru your cotton shirt
Practice on some scrap metal, check out some u tube tutorials.

 

Get a standalone MIG for your Jeep work. It is a much more versatile process for automotive.

AC only stick machines aren't good for much other than quick and dirty work on fairly heavy mild steel. If you want to tinker with stick, watch for a used AC/DC machine to come along. That will give you the ability to add a scratch start TIG rig later on if you want and will also allow you to run much better rod.