Which Welder To Buy?

“I am looking to build one of your trailers, but I need to know which welder to buy?”  or  “What type of welder do I need – 110 volt? or 220 volt?”  and  “What about other projects from your site that may pique my interest?”

Such simple questions, Right?  I wish there was a simple answer.  Well, there are a lot of short answers – particularly from people trying to sell something.   Yet, the real answer is sooooo much bigger.  To answer properly we need some background, and then some understanding of how you want to use the welder.

Welding is a ton of fun, so let’s dive into some things to think about when selecting which welder to buy.

Because there is a lot involved in making the right decision, I will not go too deep.  Often we just need to know what questions to ask, so I will point out a few things, then you can finish the research.  Hopefully these bits will help in your decision process.

Starting With Welder Basics

Most important is the MATERIAL will you be welding.  If it is Steel, there are a lot of options.  For aluminum, fewer.  If it is paper thin Titanium, the choices are limited.  Material requirements really drive the other choices, so start with material, then . . .

. . . what material THICKNESS will you weld?  The welder must easily do what you intend to give it.  Personally, I would buy one that will do at least one size thicker, and one size thinner than you intend.  (Two sizes are even better because it gives options down the road.)

Next is the WELDER TYPE -or- welding process.  The most popular types are Stick, MIG and TIG.  Here are some quick thoughts on the topic, then this link has a lot more about welding processes.

• Stick (Shielded Metal Arc Welding, SMAW)

  Usually the least expensive machines and consumables.  You can get started easily, but it is also one of the harder processes to master.  And, there is usually a lot of clean-up after welding, like chipping, grinding, etc..  You see it on YouTube with people making things, but it is an art to become good.  Many people, like me, are just hacks with a Stick, so my respect to people who are proficient.

• MIG, aka Wire Feed (Gas Metal Arc Welding, GMAW)

  MIG is arguably the most common, and most forgiving.  The machines are not hugely expensive, but they do consume a fair amount (gas, wire, tips, etc.).  This is a fast way to weld and it does not take a certification to get something reasonable.  (Look at the videos about Welding Spring Hangers.)  These are very common for big-ish things like trailer frames and cranes.

  There are 2 types.  Solid Wire with inert shielding gas (like Argon, Nitrogen, or CO2), then Flux-Core wire that creates shielding gas as the wire melts into the weld.

  While MIG welders are best with steel, they can do other materials like aluminum with the right wire and proper attachments.  One caution however, if you want to weld thin material, choose the welder wisely.  (See the stories below.)

• TIG (Gas Tungsten Arc Welding, GTAW)

  Typically considered the best weld – in looks and strength (from a skilled welder).   You can weld almost any material from very thin to super thick (depending on the capability of the machine), because these welders control the heat and filler independently.

  So why not use TIG for everything?  This method is arguably the slowest too.  Sometimes painstakingly slow compared to other methods, and it does take a fair amount of skill.  A trained eye and hand are required to achieve proper penetration in high strength applications, a beautiful weld, and to not blow holes through the thin stuff.

• There are more welding processes, like oxy-acetylene burning torches, spot welders, and others.  They each have their place, but the 3 above are the most common for DIY.
• The new and upcoming is Handheld Laser Welding.  I have seen fun videos that make it look so easy, but I have not tried one.  The cost for a good one is still out of my reach.  (We will have to sell a lot more trailer plans so I can save my pennies and get one.)

More Welder Basics:

Then there is DUTY CYCLE.  This is (sort of) a specification about how hard you can push the welder.  It is measured in percent of ON time versus Off time, and the allowable duty cycle changes as you put more power through it.  For instance, if a machine will weld 3/8 inch material thickness at 20% duty cycle, it means you can weld for 10 seconds then you have to wait for 40 seconds before you can weld again for 10 seconds.  (20% On, and 80% Off – for cooling the welding machine internals.)  A bigger, more expensive machine may do 3/8 inch material at 75% duty cycle.  (45 seconds On, 15 seconds Off.)  Only you can say if that works for you or not.

Next, QUALITY of the welder.  My nice Millermatic was stolen several years ago, so I got a cheap used substitute – and hated it.  I managed through my urgent project, but it was hard to maintain a good clean bead and produce strong welds.  I finally got so frustrated, I went and bought another Miller again – what a difference.  If you plan to weld a lot, I strongly recommend spending a little extra money and getting a good quality welder.

Side Note Of Advice:

Especially if you are new to welding, please take a class or have someone teach you a little.  Use a good welder AND a cheap one so you can feel the difference.  This is so important in choosing which welder because experience is the best teacher.  There is something to say about “Self-Taught”, but there is also something powerful about being a student of a master.

Finally, available POWER.  Yes, this was in the original question, and it is really important.  Higher voltages are almost always better with welding.  It will give longer duty cycles for the same material thickness (in general).  It is easier to pull more power for bigger thicker welds.  However, if you do not have access to 220 VAC for instance, then that helps make the choice.  See below.

Several Random Thoughts

Part of producing a good weld is familiarity with the machine.  My friend has a 110 VAC MIG flux core that he loves (though he rarely uses it).  I have used it and find it very frustrating.  Maybe I just need more practice?  Or, Maybe I am becoming a welder snob, but quality of both the machine and the welding result, mean a lot to me.

That said, for starting out, I recommend something less expensive to learn on.  Learn what you like and what you are really going to use.  In a while, if you use it a lot, you will know what you want.  Then, buy something nice.

No matter what machine you choose it takes practice, and testing to know how to achieve good results.  Weld some samples from scrap material, then break the welds to see what is happening on the inside.  How much does it penetrate?  How much effort does it take to break the weld?

Fun Stories:

A few years ago my adult son decided to buy a welder.  I taught him some growing up, but at his new house he wanted one.  For Christmas I gave him a certificate to attend a local welding class, and gave him a pile of my scrap steel.  (Yeah, boys don’t like to learn from their dads.  That is totally normal.)

A while later at his house, and noticed he had cut a bunch of the steel, and welded it in many ways!  I could tell the starting welds, and I could tell as he progressed.  What total fun!

I also recommend taking welding classes.  I see stuff on YouTube and laugh sometimes at the silliness.  Yeah, it works for them (or they think it does), so they make a video, but there are often better techniques.

At nearly age 30, even after welding since I was young, I took 2 years of welding classes at a local trade college for fun.  Studying under a master to understand the processes was eye-opening to significantly improve my welding.  Stick, MIG and TIG.  I highly recommend learning from the experts.

Choose where you will learn.  Some sources are just full of bad ideas and things that are not really true – like this article on Who Should You Believe.  YouTube seems to attract them.  However, there are also great sites for knowledge on welding – like this good overview of Welding Processes.  (Actually their whole website is good.)  Anyway, keep learning.

Consider The Extras

One of the best side purchases is the right helmet.  The newer (they have been out for years) automatic darkening helmets are a game changer.  The first time I used one (instead of flicking my head) I totally fell in love.  I highly recommend spending a little extra for a really good helmet.

Gloves and other safety equipment fall in this category of “Extras”.  Which gloves depend on which welder you choose.  Just make sure they protect from sparks and accidental touching of hot metal parts.  Clothing and shoes are also good to consider.  You can spend too much money on the greatest leather covers, or just wear some good older cloths.

Choose wisely.  When a red hot glob of metal goes down your shirt, or into your shoe, you will re-think pretty quick about your choice of clothing!  Finally, use something that protects your skin from the UV light.  Weld-sunburn is not very pleasant, and it is different than real sun-sunburn.

Another game changer for me is having the right clamps, and work space to hold things in place, straight.  See this article in our Solutions! section about storing clamps.

More Than Just Buying A Machine

The welding machine is certainly the center of welding, but there is so much more.  We consider it an Essential Tool – whichever welder you choose.  Consider these things too when thinking about which welder to buy.

1. Power Access.  As above, it is almost always better to opt for the highest power source you can.  220 VAC with 30 to 50 Amps is pretty common in the USA.  Yes, please consider the current (Amps) to run it.  Assuming you have the available voltage for your shop (garage, or basement), it is usually not a big deal to run a new circuit for the welder.
2. Space Available.  A lot of things you might weld need space to build.  A trailer for instance.  Many people will build on the driveway in front of the garage (which is great if the weather cooperates and your neighbors don’t complain).  Pick your spot, then . . .
3. Power to the right spot is a combination of the above 2 items.  To get from the outlet to my workspace, I made a few heavy gauge extension cords.  The key is getting the right ends to build the cord.
   ** As a funny side story, when first starting out, we lived in a small rented house.  To weld, I pulled out the oven and plugged in a large extension cord (6 gauge), and ran it to the garage.  It worked, but I could not weld when my wife was cooking. **
4. Consumables.  When buying a welder, consider all the things that make the welder work.  Tips, wire or sticks of various diameters, shielding gas, Cutters, Wire Brushes, Angle Grinder, Gloves, Helmet, Apron, etc.  Seems like the list just keeps going.  You do not have to buy it all at once, but please know that there is a lot more to buy than just the welder.
5. Techniques.  Finally, learn the tricks and techniques for good welding.  It is most important that the welds are strong, then work on making them pretty.  Take a class or two.  YouTube is good for some things, but learn the fundamentals of technique from an expert.  Knowledge is Power.  Other great tricks like Pre-Stressed Fabrication can be a game changer in making everything turn out right.

Does This Answer The “Which Welder” Question?

The choice of which welder to buy is more complicated than we often think.  And, a lot depends on your personal preferences.  I now have multiple welding machines for different types of projects.  For most DIY projects like trailers / cranes / presses like the plans we offer on this website, a good MIG welder does the job wonderfully.  You can get good ones from any of the major brands like Miller or Lincoln, though I personally steer clear of the cheap off-brands (like Harbor Freight).

Side Note:  Spending money on a cheap welder is a good way to make sure you progress slowly and get frustrated.  IMHO.

Choose your welder using the basics above, tempered by the available cash you have to spend.  Consider also how you might use it in the future.  A good example:  I rarely bump into duty cycle issues, but once in a while my machine will stop because I hit a thermal limit.  Then, I have to wait 5 minutes before I can continue.  For me it only happens on thick material and long welds – something I did not think I would do much.

We could go on and on into techniques of welding for different applications, and more, but I will let this suffice.  Welding is an awesome skill to have and there is nothing like having your own machine to practice all you want.  My hat is off to those who learn new skills all though life.

Good luck with your shopping.  Try Craigslist first, because people who bought nice welders and find they did not use them sometimes sell them cheap.