low_blazer
+1y
I've done alot of work with 110 and 220 units, and baggedb2200 is dead on. A 110 unit will work, but really it needs to be used by an experienced welder. You also need to remember that a good 135 amp 110 unit will weld 3/16 in a single pass. That's 2x as thick as a factory frame. Agreed, you will need to properly bevel any thicker plate, probably run a root pass plus a 2nd run, but it can be done very safely with a 110. The biggest problem I've seen as of late are guys grabbing the biggest welder they can get their hands on, turning it up and becoming a "fabricator" over night, hammering a bunch of 1/4" shit on their factory frames and calling it good. A larger 220 unit makes it alot easier to make a weld that will hold, but it also masks the lack of ability of alot of guys. It's VERY easy to weld too hot on a frame, wind up with a huge heat affected area (read: brittle) and undercut a weld, all while having a weld that looks great, and will hold for a while, possibly a long while.
For what it's worth, alot of the suspension work I did 4, 5, 6 years ago with a 110 unit is still on the road, and I have NEVER had a weld fail.
My best advice to you is, before you buy a welder, go buy some books on metalurgy and theory, maybe hit up a class at your local community college or find an experienced wedler who's willing to help, and learn the basics before you start sticking shit to your truck.