The abilities gained when one ventures into the world of welding is something that cannot be appreciated until experienced. From simple chores like shaving trim to more complex tasks like installing a front clip, the possibilities are endless when a good machine and an adequate operator are combined. The simple ability to fuse two metals together opens up such a variety of possibilities that it's impossible to even scratch the surface. Many of the tasks previously outsourced to friends or local shops that were equipped to do such jobs can actually be done at home with the proper machine.
Those of us who are outfitted with such equipment and the knowledge of how to use it know these benefits firsthand. Many homebuilders, unfortunately, see the money factor as a just reason not to have a welder around, with a learning curve too steep to justify the few times the machine would be used. And, while that may still hold true with the more advanced TIG (tungsten inert gas) and production MIG (metal inert gas) welding machines, there are a handful of truly plug-and-play machines built specifically with the homebuilder in mind, making that jump into the welding world that much easier.
The Millermatic 140 with Auto-Set, an Elite Series auto-darkening helmet, and a pair of MIG gloves make for a very stripped-down welding station for the beginner.
Before one drives down to the local welding supply store to purchase a machine, however, there are a few decisions to be made, based not only on one's abilities and experience, but also on the abilities that will be required of the machine. If this is your first foray into the world of welding, a $7,000 TIG machine is not only overkill, but it's also quite a bit more complicating than a good starter MIG machine. With such a vast difference in machines available today, we went to the source, Miller Electric, and had the guys give us the 411 on not only what equipment is out there for experienced welders, but what the company offers for those homebuilders with little or no experience. Not surprisingly, Miller already had two MIG machines designed strictly for hot rodders, with Auto-Set capabilities that allow the user to set the wire size and the thickness of material to be welded, and off you go. No longer having to guess the wire-feed speed or the arc volts, a beginner can simply adjust the settings to his application and start a-buzzin'.
Armed with the knowledge that there are welding machines designed exclusively for the entry level and occasional welder, we decided there was no excuse for any hot rodder to not have a welder of some sort around the garage. But, there are a number of things to consider before stepping up to the plate for the first time. This month, we're going to cover the basics of getting a welding setup up and running for the first time, and while this is meant for those guys in their home garage with little to no welding experience, you more "long in the tooth" rodders might find some of this stuff interesting, too. We'll walk you through the entire selection process, from what machine to buy to what safety equipment and consumables you'll need, and we'll even check out some accessories that can improve the welding experience.
The Auto-Set function is also available on the Millermatic 180. The added amperage of the MM180 allows single-pass welding of material up to 5/16-inch and comes ready to go, sans gas bottle.
Getting Started
One of the most difficult choices made when the first-time buyer goes welder shopping is which machine to purchase. Price, compatibility with existing equipment/hardware, application, and frequency of use are among the most common determining factors when purchasing a basic machine. And, while all three of these denominators have their respected importance, none of them should be considered as an end-all deciding factor as to which machine to purchase.
Since the TIG process is a relatively refined welding procedure and requires more experience to perform properly, and stick welding is just too unrefined for most hot rod-building applications, we're going to concentrate on the wire-feed or MIG-welding process. The MIG process is advantageous to the beginner for a number of reasons, the least of which is that it is the easiest to learn. The "squeeze and drag" technique allows most any user to familiarize themselves quickly, while the simplicity of settings means learning to lay down proper welds is as simple as turning a few dials. The MIG process also allows higher welding speeds, which makes installing brackets and such a quick and easy task. It is also cleaner than stick or flux-cored welding since a shielded gas is used, making little slag cleanup necessary. These characteristics make MIG welding the choice for both beginners and intermediate home welders alike.
Both the MM140 and the MM180 machines make a breeze out of sheetmetal work like patch-panel repairs and top chops.
Choosing A Machine
Now that we've decided on the process we're going to use, it's time to look at the two machines Miller recommends for the basic homebuilder-the Millermatic 140 and 180. Nearly identical in appearance, there are a number of important differences between the two machines. For starters, the MM140 uses 115V while the MM180 uses 230V. What does this mean? For most of us, this means the MM140 will plug into any standard plug in the house, which is handy if you want to work in the kitchen during the winter, although not recommended if you're married! The MM180, on the other hand, requires a 230V circuit, which may need to be installed by a qualified electrician if your garage is not so equipped, but it's usually a fairly simple task. If your garage isn't properly equipped, check into adding the 230V circuit before choosing a machine solely based on compatibility with your existing outlets.
So, why buy a welder that requires a 230V outlet as opposed to one you can plug into any outlet around the house, as well as your buddy's garage? The answer is simple: more power. While the amperage range for the MM180 (30-180) is only slightly higher than the MM140 (30-140), the increased 230V power yields a duty cycle that is higher, allowing it to weld up to 5/16-inch-thick steel in a single pass, compared to 3/16-inch for the MM140. While either machine is capable of handling most any application a hot rod build could throw at it, the MM180 is capable of welding slightly thicker material, making it more appropriate for chassis work, and the like.
One of the newest features to grace both the MM140 and the MM180 is the Miller-exclusive Auto-Set control. This breakthrough control automatically sets your welder to the proper parameters with a twist of the dial. Compatible with either 0.024- or 0.030-inch solid wire (75 percent argon / 25 percent CO2), simply choose the wire size installed in the machine, set the material thickness, and start welding-the machine does all the thinking for you! This means no more experimenting with wire-feed speed or arc voltage. Each also features Smooth-Start technology that provides a smooth, spatter-free start and a "tip saver" short-circuit protection that shuts down output power when the tip is shortened to the work.
While the MM140 machine can tackle material up to 3/16-inch, larger jobs like chassis fabrication are better suited to the 230V MM180. |  | 
Once savvy with a welder, there's no limit to what can be fabricated, and Miller's Auto-Set feature makes it easy to go from 24-gauge sheetmetal to 3/16-inch plate. |
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One of the coolest features of both the MM140 and the MM180 is the ability to MIG-weld aluminum from 18-gauge to 1/4-inch using the Miller Spoolmate 100. Priced around $200, it's truly one of the cheapest choices when it comes to MIG-welding aluminum. | 
Not sure which unit is the one for you? Miller offers the easy-to-use SmartSelector program on its Web site that allows you to choose the process, such as MIG or TIG welding, and helps you navigate to the right welder based on your needs. |
The Auto-Set function allows the user to set the wire diameter, either 0.024- or 0.030-inch, and material thickness to be welded, and the machine does the thinking for you-no more guessing wire speeds and voltage settings. | 
The Pro-Hobby Series of welding helmets is Miller's entry-level line of auto-darkening helmets and retail for about $150. | 
Instead of guessing the thickness of material to be welded, Miller includes a material thickness gauge as part of either welder package. Determine the thickness of material to be used, adjust the Auto-Set dials, and get a-buzzin'. |