O/A ARC and MIG

[tomg303]

Hey binder planet,

I've got some questions about welding body panels. I have experience with O/A and Arc welding but none with mig or flux. I don't have access to a 230 outlet but I could wire one if I had to . I'm just lookin to replace some rusty floors. With a budget of $200 what welder would you recommend. I'm not worried about ugly welds so a $100 HF flux looks appealing. Arc are also pretty cheap used. In fact I saw a wards 290 amp today with all the gear for $100. Let me know a cheap weekend warrior way to do it.

[Dennis Bernth]

If you already have O/A, then the cheapest way to go is to use that, either by welding or brazing the panels in. If you get the pre fluxed brazing rod it's simple, it uses less heat than welding so you get less warping, and the bead grinds down easily.
You don't really need a 230 volt welder to do body panels, if you take a little time I'm betting that you can find a decent little 110V MIG on CL for near what you want to spend. My experience (years ago, but still experience) was that the older ones had plastic wire drives and were junk. I'd rather have a used Century, Miller, Lincoln, or Blue Point than a new HF welder. And if you can spring for it, gas is much nicer than flux core, although if you're working outdoors flux core might be the way to go since you don't lose your gas shield in the wind. Another advantage to buying a used 110v MIG is that anybody selling it will have a plug; take along some metal and a hood and insist on trying it out, that way you know it works before you leave.

[Bill usn-1]

The flux burns hotter then the gas so doing body panels sometimes leaves burn thru holes.
Use light amps and thin wire.
If you go with a flux machine i would at least get one with the gas kit so when you get ready, you can upgrade to the gas.

Most small machines are 110 anyways so not a problem.
Some 220 machines will run on 110 or 220.

[tomg303]

Would the O/A be more difficult than the flux core? Probably more time consuming

[kb'sforme]

Well that's subjective. OA is a slower process, but depending on your skill at it not a huge difference in time for laying down a bead. The welds can be as nice as a tig with the right rods and skill. Once welded the bead will need little grinding to finish and it will smooth out easy.
With flux core you might get the weld done quicker. But it will not be as nice looking, will require more finish work. And does not smooth out as nice due to a harder weld. Also the HAZ is different for the two and will play into the amount of finish work needed.
Personally I use OA for all my sheet metal work. But I use an aircraft style torch which makes life a little easier. I do like a mig for tacking things and general fab work.