Well gas will be cleaner than flux, but not necessarily stronger.  If you
only weld occasionally, I would not bother with renting or buying a gas
bottle.
Good you got lots of amps available.  That makes a big difference.

120 volt welders can't produce enough heat to weld 1/4" 'properly'.

To maximize the amount of heat a small welder will produce:
- Heavy gauge extension cord
- Hold tip as close to work as possible
- Push the bead, as opposed to pull.  Push = like driving forward.  Pull =
like driving in reverse
- Preheat the piece with a propane or acetylene torch
- Move torch slow, steady and smoothly.  In a controlled motion.

fwiw, I wouldn't be welding any trailer hitches with a 120 volt welder.

If anybody in Calgary needs simple welding jobs like that done, I do it for
free for local vanagon owners.

Gary Lee
www.vwrack.com

----- Original Message -----
From: "neil N" <musomuso@gmail.com>
To: "Gary Lee www.vwrack.com" <gary2a@telus.net>
Cc: <vanagon@gerry.vanagon.com>
Sent: Saturday, March 15, 2008 11:44 PM
Subject: Re: WAS: building carrier bar..... NOW: Test Weld PIC

> Thanks for the pointers Gary.
>
> Yup. 120, MIG with flux but am running 12 gauge from a 20 amp breaker.
> I found I could go quite slow on the 1/4" plate and will slow it down
> more. Quite a contrast to the practice welds I tried on the scrap
> exhaust tube.
>
> I may end up using 1/8" plate and angle instead of the 1/4". Those
> were free scrap pieces so I gave it a whirl.
>
> I'm learning pretty fast, but there's lots to learn even with just
> setting up correctly. Proper lighting, material and work position etc.
>
> It'll be nice to get set up with gas. The flux puts out too much smoke
> and spatter.
>
> Thanks,
>
> Neil.
>
> On Sat, Mar 15, 2008 at 10:30 PM, Gary Lee www.vwrack.com
> <gary2a@telus.net> wrote:
>>  >Now I KNOW I'll get this load bar done. Too bad I can't get material
>>   >til Tuesday!
>>
>>   > http://tubaneil.googlepages.com/1stlargeweld
>>
>>   >Thanks guys,
>>   >Neil.
>>
>>  Neil,
>>  Looking at your picture, I'd say you are using a 120 volt MIG.
>>  Fluxcore?
>>  That would give you marginal penetration on material as thick as in
>>  your picture.  Go slowly and weave back and forth.  I hold the torch
>>  with two hands, one on the trigger and the other near the tip. Hold
>>  the torch close in to the material, as little 'stick out' and
>>  possible.  Plug your welder in as close to the breaker box as
>>  possible.  Avoid using extension cords.
>>
>>  Gary Lee
>>  www.vwrack.com
>>
>
>
>
> --
> Neil Nicholson. 1981 Air Cooled Westfalia - "Jaco"
>
> http://web.mac.com/tubaneil
> http://tubaneil.googlepages.com/
>
>
> --
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