For the welder, whatever you do, get a 240v machine. You can really only affectively MIG (gas) up to approx. 1/8" with a 120v machine (and it will struggle BTW, duty cycle). If you decide to weld thicker you will have to flux core (gasless) which will only be good to approx. ~1/4". I do not like welding flux core. It is a little more forgiving (in terms of metal preparation) ; you can get away with a little dirtier joint, but lays a sloppier bead, not to mention you have to clean the crap off afterwards. You can lay down smooth welds in MIG process with a clean joint. If you don't get a 240v machine at first and go with a 120, you will outgrow it in no time flat. The only time I ever use a 120v welder is to weld sheet metal. Don't cheap out on the welder. Get a good one and keep it for a long time.

My favorite machine for this type of stuff (off-road projects) is the Miller Millermatic MM180. This machine will easily MIG 1/4" in one pass and flux even bigger. Hobart is also a rebadged Miller with slight variations in terms of material type of certain internal parts. I hear they are good welders. A little cheaper with good performance. I believe their comparable model is the Hobart Handler series HH187 (don't quote me on that, trying to go by memory). I would recommend either of these two welders. You can't go wrong with either based on experience and hearsay.


For a decent affordable plasma cutter, reference this thread: Plasma Cutters, Plasma/TIG/Stick Combos (NOW AFFORDABLE!) - Pirate4x4.Com Bulletin Board

Most guys are running their 40 amp machine and having great results. I stepped it up to their 60 amp plasma and can draw on 1/2" plate, no problem. Either way, you won't find a cheaper plasma that performs as good as this one does. I have had mine for 2 years now with no problems and it cuts straight. During this time I have used the hell out of it as well. Best $600.00 I ever spent. The 40 amp models are a lot cheaper than that! Granted they are Chinese made, but Parker offers a warranty. A Great bang for the buck. Brand name plasmas are going for up to 3-4 times more than the Parker.