I am looking into chopping my 4runner and will be adding tubing and possibly full roll cage or exo cage.
What size DOM tubing do I need?
And will this welder work for my needs?http://www.homedepot.com/webapp/wcs/...ctId=100039229

This will probably be the only time I NEED a welder but wouldnt mind having something for future needs also. For now I don't want to spend much money as I need the money for materials. Is this enough, to much, or not enough to weld a cage and sheetmetal?

 

no that welder is good for metal like pop cans, save up and get a miller, lincoln, or hobart but with 220v. You will be get way more out of one of these than that lil guy, If you are just going to use it for this job just go rent one for a month its shouldnt cost more than $300 As far as the tubing it depends maybe 1/4 thick? but im just guessing on that one.

 

the weldpaks are actually great welders (as long as you go for a 140 or higher). I personally have a weldpak 140 and it will weld 1/4" no problem as long as you bevel the joints and you make two passes, one to join the pieces and one to fill the bevel. You should be beveling the joints on stuff that thick to get full penetration anyway.

When I have to weld some serious stuff together I go to a public workshop I have membership at and use their big beefy 220V MIG or TIG welder.

If this is your first project where you're welding I would say do not do an exo cage because the point of an exo cage is to keep you safe. If you have sloppy welds all over it, its not going to do that. Start with sliders, they're pretty simple. Then move to front and rear bumpers. From there you can weld in an exo cage, you should have enough experience by then.

edit: Also, you say this is the only time you'll probably need a welder. Well, if you NEED an exo, you're going to be bashing the poo out of your truck. And if that's true, then you're going to need that welder to fix/strengthen/replace damaged parts.

 

Well the main reason right now is that I am chopping the back of the 4runner. I plan to install a rear section off of a truck but would like to create some type of roll bar/cage to support where I have cut into. I have welded before and yes I will be practicing before I go on to the cage but I just want to know if that welder will do it. Do you know the thickest of tubing to be used. And when you say bevel you are referring to grinding the edges at an angle, welding a line clean it up a little and weld another fine line? ALso I have heard of taking a smaller diameter pipe to use as a but joint. Drilling a hole on each end tacking it, leaving a gap between the two joints and welding that.