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In that chart the Millermatic is rated at 210 amps but has a duty cycle of 60% while operating at 160 amps. All of the macines listed can be used single phase.
Here is Miller's chart for thickness guidelines.
http://www.millerwelds.com/products/mig/allinone_products.html
You can always get better penetration if you bevel the edges of you metal
With an amperage range of 45-80 I don't see much use for it. The amperage doesn't go low enough to weld thin sheet metal yet doesn't go high enough to weld anything 3/16" or thicker. Do yourself a favor and get something 220 volt.
Is this going to protect the rear quater panel? Some thing like this maybe:
If so you will need a press brake. Most sheet metal brakes are only rated to 16 gauge, so you mich want to check with local steel yards. The steel yard here will bend anything you want and they do thicker stuff that...
A while ago I heard that Miller used copper windings and Hobart used steel, and Miller machines had steel gears where hobart had plastic. This would indicate that the Miller is built better and will last longer.
I have used it on the diff cover and frame of my truck and haven't had any problems. I spent a good amount of time preping the surface for good adhesion. It really depend on how good of a prep job you do and what you scrape your rig up agains. Branches and brush won't be an issue.
I used herculiner on mine. So far its been about 2 years and I haven't had any problems with chipping or peeling. I can't comment on how it cleans up because I haven't washed my Jeep since I built my bumper.
Heres a picture of how it looks.
I can't say that I have ever heard of CREW tubing. HREW is Hot Rolled Electric Weld and is first bent into square tubing, then welded and made into round tubing. As far as plate steel and sheet metal, cold rolled is very accurate when it comes to dimensions. Cold rolled also doesn't have any...
My Interpretation of the Omega hydraulic control units under the price for the press would include the ram, line, and pump. Maybe I am looking at the web page wrong, but it not you get a 25 ton hydraulic setup for $210.95 and you just need to build a frame for it.
I agree that you should clean the mil scale off of the metal before you weld. Although your not going to have a problem striking an arc, the puddle will act differntly and your weld will be contaminaded. Its not more toxic to weld without removing the mil scale. Mil scale is simply impurities...
Before you do anything wash it aggressivly with a high detergent soap like Dawn or Tide. Then hit is with a good wax and grease remover. Start sanding on your current paint with some 240 and then 400 both wet on a long board. Use a good epoxy primer to ensure good adhesion. Spray your sealer and...
I would get something like this http://cgi.ebay.com/WILLSON-6000-CONTINUOUS-FLOW-SUPPLIED-AIR-RESPIRATOR_W0QQitemZ7585335355QQcategoryZ11905QQssPageNameZWDVWQQrdZ1QQcmdZViewItem
I haven't used this exact one, but I use a similar fresh air hood. They work great and don't really get in your way...