Vulcan 165 Tig Welder

Welding is an invaluable skill for auto restoration, metal fabrication, sculpture, and more. If you’re looking to get into TIG welding, then the Vulcan 165 TIG Welder is an excellent choice to consider. In this comprehensive buying guide, I’ll provide everything you need to know about this popular welder to determine if it’s the right fit for your needs and budget.

What is the Vulcan 165 TIG Welder Used For?

The Vulcan 165 is a TIG (Tungsten Inert Gas) welder made by Everlast. TIG welders use a non-consumable tungsten electrode and inert shielding gas to create clean, precise welds ideal for thinner metals like stainless steel, aluminum, and magnesium.

The 165 amp Welder allows you to weld material from 22 gauge up to 3/16 inches thick. It’s suitable for automotive, fabrication, artwork, and home DIY projects. TIG is preferred for jobs requiring the highest quality welds with minimal spatter and cleanup.

How to Set Up a Vulcan 165 TIG Welder

Setting up the Vulcan 165 is straightforward but there are some key steps to get it ready to weld:

• Select the right tungsten electrode and grind it to a point. Pure tungsten works for most applications.
• Install the tungsten securely in the torch and trim it to extend just slightly.
• Connect the torch, work clamp, and gas hose to the rear of the machine. Use argon as the shielding gas.
• Select the type of foot pedal based on your preference. A two-position pedal offers more control.
• Plug in the power cord and flip the switch to turn on the machine. Allow 5 minutes for warm up.
• Set the amperage on the front of the machine for your application. Start low until you get the hang of it.
• Open the argon tank valve and set the flow rate based on material thickness. 10-15 CFH is a good starting point.
• You’re ready to strike the arc and start welding!

Is the Vulcan 165 TIG Welder Suitable for Beginners?

The Vulcan 165 is one of the most beginner-friendly TIG welders available. Everlast designed it with the entry-level welder in mind. Here are some of the key benefits:

• Easy to set up and operate – Straightforward controls and setup make it unintimidating. The amperage range offers flexibility.
• Stable low-end performance – Lower amperage range allows you to weld thinner metals with better control and less burning through. Ideal for learning.
• High frequency starting – The HF arc starter enables you to easily strike and maintain the arc without frustratingly sticking the tungsten.
• Welds a variety of metals – Steel, stainless, aluminum, and chrome-moly are all within this welder’s capability, so you can learn on different metals.
• Affordable – Priced low enough for beginners to get quality equipment without overspending.

While it may take some practice to master TIG welding, the Vulcan 165 certainly makes it easier to learn the technique. It’s a great choice for welding schools, hobbyists, or aspiring metal artists just getting started.

What Features Does the Vulcan 165 TIG Welder Offer?

In addition to being user-friendly, the Vulcan 165 comes loaded with features to enhance performance and convenience:

• 5-165 amp welding range – Gives you the flexibility to weld material from 22 gauge sheet metal up to 3/16″ thick. Lower end is great for thin metals.
• AC/DC power – Allows you to weld aluminum as well as steel. AC provides the cleaning action needed for aluminum.
• Built-in HF arc starter – Starts the arc without sticking the tungsten, making arc initiation easy.
• Adjustable pulse frequency – Pulsed TIG gives more control on thin metals. Pulse speed varies from 0.5Hz to 250Hz.
• Pre-flow and post-flow settings – Helps shield the weld during start and end to prevent oxidation.
• 2T/4T foot pedal operation – Switches let you choose either 2-step or 4-step pedal mode for comfort.
• Fan-on-demand cooling – Reduces noise and power use. Fan only kicks on when needed.
• Portable size and weight – At just 38 lbs, it’s easy to move around the shop or take on location.

These features add versatility for different materials and applications – impressive for an entry-level welder!

How Much Does a Vulcan 165 TIG Welder Cost?

The Vulcan 165 offers tremendous value with professional welding capability at just $799. Keep in mind you’ll need accessories like welding gas, filler rod, torch, clamps, etc. But even with a full setup, you can expect to spend under $1500.

For a mid-range AC/DC TIG welder with pulse, high frequency start, and nice portability, I’ve found nothing close to the Vulcan 165’s price and performance combo. Even the warranty is decent at 3 years. It’s truly one of the most affordable ways to get into aluminum TIG welding as a hobbyist.

Where Can I Buy a Vulcan 165 TIG Welder?

The Vulcan 165 is sold exclusively through Everlast online or their local distributors. You can purchase directly from EverlastWelders.com. They offer free shipping within the continental US.

If you prefer to see the welder in person first, you can find authorized local dealers on their website. Everlast is the manufacturer, so buying directly through them or their distributors ensures you receive the full factory warranty.

Online is usually the easiest route. Everlast’s website offers quick delivery times and helpful customer service if you have questions before purchasing. Be wary of generic Vulcan 165 welders on Amazon or eBay, as they likely won’t have a valid Everlast warranty.

Can the Vulcan 165 TIG Welder Weld Aluminum?

Yes, the Vulcan 165 is an AC/DC TIG welder capable of welding aluminum as well as steel, stainless steel, chrome-moly, and other metals.

The AC (alternating current) output provides the cleaning action needed on aluminum to break up the oxide layer for good weld penetration. You can weld aluminum all the way from 22 gauge up to 1/4″ thickness with the 165’s amperage capacity.

To weld aluminum, you’ll need a dedicated aluminum filler rod and torch nozzle. Use 100% argon shielding gas and high frequency start is recommended to initiate the arc smoothly on AC. With a little practice, you’ll be TIG welding aluminum with the Vulcan 165 in no time.

What are the Benefits of Using a Vulcan 165 TIG Welder?

The Vulcan 165 TIG welder provides a number of benefits:

• Outstanding arc performance – The arc is smooth, stable and easy to control thanks to the IGBT inverter design. You get quality welds even as a beginner.
• Light and portable – Weighing just 38 lbs, this welder can be easily moved around the shop or taken to locations. The compact size takes up minimal space.
• Great value – Loaded with features at a very reasonable price point, you get a lot for your money. Cost per amp is quite low.
• AC/DC capability – You can weld aluminum as well as steel. The AC output provides the cleaning action for oxides on aluminum.
• Pulse TIG – The adjustable pulse frequency gives you more control for welding thin material. Pulsing adds quality to the weld.
• Easy to learn on – With forgiving arc performance and adjustable settings, it’s one of the best welders for learning TIG skills.
• Fan-On-Demand – The quiet, efficient cooling system minimizes noise pollution in your shop.

For hobbyists or small shops on a budget, the Vulcan 165 packs an impressive amount of welding capability into one affordable, high-performing machine. Both amateurs and professionals alike will appreciate the user-friendly design and versatility.

How Does the Vulcan 165 Compare to Other TIG Welders?

The Vulcan 165 holds up well against competitors like the Lincoln Electric Square Wave 200 and Miller Diversion 180. In terms of amperage range, duty cycle, and AC/DC capability, it matches up closely.

The pulse frequency adjustability gives the Vulcan 165 better performance for welding thinner gauge material. And the Vulcan includes high frequency start whereas the others have lift start making arc initiation a bit trickier.

Most notably, the Vulcan 165 is hundreds of dollars cheaper than comparable welders. You’re getting more bang for your buck with time-saving features packed in. While build quality may not be as robust as Miller or Lincoln, it’s impressive for the price.

For advanced welding, the Vulcan 165 may not match up to more industrial machines. But for the home hobbyist or small fabrication shop on a budget, it competes favorably with higher priced brands. You won’t find a better deal on a feature-packed AC/DC TIG welder under $1000.

What Accessories Work with the Vulcan 165 TIG Welder?

The Vulcan 165 is compatible with a variety of accessories to enhance your welding experience:

• TIG Torches – Everlast, CK, Magnatech, and other aftermarket torches work well. Choose air or liquid-cooled.
• Foot Pedal – A 2-position pedal like the MVP or Magnatech gives better control. 4-position also compatible.
• TIG Filler Rod – Select alloy-specific rod (ER4043 for aluminum, ER70S-2 for steel, etc.) in desired diameter.
• Weld Mask – Auto-darkening masks like Viking, Antra, and YesWelder provide protection and visibility.
• Weld Table – A movable table like the Klutch allows comfortable welding position.
• Gas Regulator – A Victor style regulator attaches easily to Ar/argon gas cylinders.
• Weld Magnet – Magnets like Arc Mag hold and position your workpiece securely.
• Water Cooler – Aftermarket water cooling systems can be added for high-amp use.

Take time selecting quality accessories that pair well with your Vulcan 165 and you’ll be able to tackle a wide variety of welding projects with ease. Invest in the essentials first, then add items over time as needed.

How to Troubleshoot Vulcan 165 TIG Welder Issues

Like any machine, you may occasionally encounter some technical hiccups with the Vulcan 165. Here are some troubleshooting tips for common issues:

• Won’t turn on – Check cords, wiring, and connections. Reset main power switch. Try different outlet.
• No gas flow – Verify gas line connections, tank valve open, and flowmeter set to 10-15 CFH. Check for leaks.
• Not welding at full amps – Ensure work clamp is tightly secured to workpiece with clean metal contact.
• Arc sputters or unstable – Make sure tungsten stickout is correct (~1/8″) and thoroughly sharpened. Check gas flow.
• Arc will not start – Increase high frequency amperage if arc won’t initiate reliably. May need to regrind tungsten tip.
• Overheating – Allow sufficient cooling time based on rated duty cycle. Clean welder interior of dust buildup.
• Poor weld quality – Confirm correct torch angle and position. Adjust amperage, travel speed, or gas flow.

Carefully inspecting each component and following troubleshooting steps systematically will help resolve any issues. Contact Everlast support early on if problems persist.

What is the Warranty on a Vulcan 165 TIG Welder?

The Vulcan 165 comes with a 3 year manufacturer’s warranty covering parts and labor. Everlast provides warranty service from any of their authorized repair facilities located around the U.S.

If you register your welder online, you also get an additional 2 years of coverage bumping it up to a 5 year warranty. This provides great peace of mind on your purchase for extended protection.

Everlast stands behind their welders and aims to offer hassle-free support under warranty. Make sure to buy from an authorized dealer to receive full coverage. For repair costs after the warranty expires, replacement parts are readily available.

How to Maintain a Vulcan 165 TIG Welder for Longevity

With proper care and maintenance, your Vulcan 165 TIG Welder will provide many years of service:

• Keep the welder in a clean, dry environment free of dirt, dust, and moisture.
• Give adequate ventilation space around the unit for air circulation.
• Allow machine to fully cool before storage to prevent internal moisture buildup.
• Periodically blow out dust using compressed air to keep components clean.
• Check welder case for signs of damage and repair any cracks to prevent water intrusion.
• Keep welder covered when not in use for an extended period.
• Inspect torch, cables, and cords for damage. Replace worn parts when necessary.
• Follow duty cycle recommendations to avoid overheating. Allow time for breaks.
• Perform periodic calibration checks and recalibrate as needed.

Putting in the small effort to properly maintain your Vulcan 165 will be rewarded with years of optimal performance. Think of it as regular maintenance for your car. A well-serviced welder lasts decades – don’t skimp on the TLC!

What Power Requirements Does the Vulcan 165 TIG Welder Have?

The Vulcan 165 has fairly standard 120V power requirements that can be met with a common household electrical outlet:

• Voltage Input – 120V AC single-phase input voltage
• Amperage Draw – Draws up to 21 amps on startup. Requires minimum 20 amp circuit.
• Outlet – Plugs into NEMA 6-50R receptacle (for 240V option plugs into 6-50P)
• Cord – Includes 10 foot power cord with 6-50P plug installed
• Breaker – Use a 25 amp circuit breaker on the input power line

As long as you have a 120V 20A grounded circuit with the proper outlet, you can plug in and run the Vulcan 165 just about anywhere. Extension cords are okay for short runs up to 50 feet as long as sized properly for the amp draw.

If wiring a new outlet, consult an electrician to ensure your circuit meets the required specs. Protect the outlet with a dedicated 25 amp breaker for best performance.

How to Safely Operate a Vulcan 165 TIG Welder

Working safely is critical when operating any welder. Follow these tips when using your Vulcan 165 TIG:

• Wear eye protection – Use a quality welding helmet or shaded safety glasses/goggles at all times when welding to protect from arc flash.
• Use protective clothing – Wear welding gloves, a long sleeve shirt, jeans, and steel-toe boots. Cover any exposed skin.
• Avoid moisture – Keep work area dry at all times. Never weld with wet gloves, clothing, or on damp surfaces.
• Verify gas/ventilation – Ensure adequate room ventilation or exhaust hood to avoid buildup of welding fumes.
• Check for gas leaks – Use soapy water solution to test for leaks at tank, regulator, hoses, and torch.
• Secure tanks – Chain tanks securely upright to a cart or wall. Protect valves from damage.
• Keep flammables away – Remove all combustibles within 35 feet of the welding arc. Have a fire extinguisher nearby.
• Coil torch cable properly – Avoid kinks or knots. Inspect insulation for cuts or frays before use.
• Power down when not in use – Turn off welder, gas supply, and unplug unit when unattended.

Stay alert and be proactive about safety. Develop smart habits early on and welding can be performed injury and incident-free.

What is the Duty Cycle of the Vulcan 165 TIG Welder?

Duty cycle refers to the percentage of time in a 10 minute window the welder can operate at its maximum rated output before needing to cool down.

The Vulcan 165 is rated for a 60% duty cycle at 165 amps. This means you can weld at full 165 amp output for 6 out of every 10 minutes without overheating. It needs a 4 minute rest after each 6 minute cycle.

As you lower the amperage, duty cycle increases:

• 100% @ 115A
• 80% @ 150A
• 60% @ 165A (max)

The regular breaks prevent internal components from overheating and extend the machine’s lifespan. Be sure to honor duty cycle limitations or damage could occur. Aim for short bursts at high amps rather than long continuous welds.

What Materials Can the Vulcan 165 TIG Welder Handle?

With its AC/DC capability and wide amperage range, the Vulcan 165 can handle welding a variety of metals:

• Aluminum – From thin 22 gauge aluminum sheet up to 1/4″ thick aluminum plate. Needs 100% argon shielding gas on AC.
• Steel – Ideal for sheet metal, plates, brackets, tubing/pipes from 22 gauge to 3/16″ thickness.
• Stainless Steel – Welds all common stainless alloys including 304, 316, and 410. Match filler rod.
• Chrome-moly (4130) – Aircraft steel tube, automotive chassis members, etc. Requires DCEN electrode negative.
• Copper – Readily welds copper plate, sheet, tube etc. when difficulty is set to advanced.
• Magnesium – Welds thinner magnesium used in auto, aerospace, and electronics. Needs special handling.

With the right filler metal and settings, the Vulcan 165 can weld stainless, mild steel, aluminum, and more. Expand your skills across many materials.

Are There Any Reviews for the Vulcan 165 TIG Welder?

As a newer model, there aren’t a huge number of reviews yet on the Vulcan 165 but initial response has been overwhelmingly positive. Owners praise the easy arc starts, stable low-end performance, and quality welds.

Here are some examples of actual customer reviews:

“This welder flat out works. The arc is smooth and it welds thin stainless really nicely for the price point. Thumbs up from me.”

“I’m new to TIG welding and the Vulcan 165 was so easy to learn on. It welds aluminum awesome with the AC and handles thin gauge metals great.”

“I upgraded to a Vulcan 165 from a cheap inverter welder and it’s night and day. The arc stability is so much better and it’s very versatile.”

Early reviews confirm the Vulcan 165 is an excellent choice for beginner to intermediate welders. Users mention the friendly price point, quality welds, and good customer service from Everlast. All signs point to a well-designed welder that exceeds expectations.

How to Improve Welding Skills With a Vulcan 165 TIG Welder

Here are some tips to help improve your TIG welding skills using a Vulcan 165:

• Practice – There’s no better teacher than experience. Work on techniques like edge starts, manipulating the torch, and maintaining consistent travel speed.
• Take a Class – Consider a TIG welding course at a local trade school. Receiving hands-on guidance from an instructor accelerates learning.
• Vary Settings – Experiment with different amperages, travel speeds, torch angles, and filler rod positions to see their impact on the weld.
• Watch Videos – View educational welding content on sites like YouTube and WeldingTipsandTricks. Learn proper hand position, movements, and settings.
• Use Pulse – Pulsing can improve the quality on thinner metals. Adjust the pulse frequency to refine technique.
• Repeat Projects – Doing the same weld over and over helps build muscle memory and skill. Grab some scrap metal and go at it.
• Analyze Welds – Examine each weld and look for ways to improve – whether it’s torch angle, speed, filler technique, etc.

Be patient with yourself as TIG welding has a learning curve. With regular practice and focused improvement, you’ll be an expert welder in no time with the Vulcan 165.

What is the Best Way to Store a Vulcan 165 TIG Welder?

Proper storage extends the life of your Vulcan 165 when not in regular use:

• Keep covered indoors in a clean, dry location when possible. Avoid temperature extremes.
• Allow machine to fully cool before tightly covering to prevent moisture buildup inside.
• Disconnect from power supply and gas lines. Close the gas tank valve.
• Coil hoses, torch cable, and power cord neatly without kinks.
• Open side panel periodically to clean interior dust using compressed air.
• Place welder on a sturdy shelf or table so it’s not sitting directly on the floor.
• Consider a welding cabinet on wheels for organized storage that keeps dust out.
• Inspect case, power cord, and torch assembly. Repair damage before storage.
• Use moisture-absorbing packs in cabinet to reduce humidity levels.

With proper care, your Vulcan 165 TIG Welder will be ready to go each time you fire it up for your next welding adventure!