Vulcan 205 Tig Welder

Discovering the Perfect TIG Welder for Home and Small Shop Use

As a welder and metal fabricator, having the right tools for the job is crucial for creating high-quality welds efficiently. When it comes to TIG (Tungsten Inert Gas) welding, one of the most popular welders for hobbyists and small welding shops is the Vulcan 205 TIG Welder.

This versatile, compact TIG machine allows you to weld thin metals like stainless steel, aluminum, and mild steel using the TIG welding process. But with so many welders on the market, how do you know if the Vulcan 205 is the right choice for your needs?

In this comprehensive Vulcan 205 TIG Welder buying guide, I’ll cover everything you need to know about this welder to decide if it’s the best TIG welder for you. We’ll look at the Vulcan 205’s key features, capabilities, setup, accessories, reviews from other users, and much more.

Let’s get started!

What is the Vulcan 205 TIG Welder Used For?

The Vulcan 205 is designed as an entry-level AC/DC TIG welder for light industrial, home workshop, auto restoration, and motorsports applications. Its compact size makes it easy to transport to job sites.

This welder is versatile enough for welding:

• Thin stainless steel, mild steel, and aluminum
• Sheet metal, auto bodies, motorcycle frames
• Pipe fittings and tubing
• Custom fabrication and repair jobs

The Vulcan 205 allows you to weld metals from 24ga up to 3/16” thickness in a single pass. With an adjustable AC balance control, you can fine-tune the arc for optimized aluminum welding.

It’s not designed for heavy duty fabrication, but offers enough power for most home workshop applications. The Vulcan 205 is a great match if you need an affordable TIG welder for autobody work, small part fabrication, or sculpture.

How to Set Up a Vulcan 205 TIG Welder

One advantage of the Vulcan 205 is that it’s designed to be easy to setup and use. Here are the basic steps to set it up for TIG welding:

1. Position the Welder

Place the welder on a sturdy, dry surface in your workspace. Make sure it’s near a 120V or 240V power receptacle.

2. Install the Shielding Gas Cylinder

Attach an argon or argon/helium TIG welding gas cylinder and regulator to the rear gas inlet. Tighten the connection securely.

3. Select the Proper Tungsten Electrode

Choose the right tungsten diameter and tip shape for the metal thickness you’ll be welding. Grind the electrode tip before inserting it into the TIG torch.

4. Connect the Torch and Cables

Insert the TIG torch head into the receptacle on the front of the welder. Connect the work clamp to the “-” connector.

5. Plug In Power and Gas

Plug the power cord into a suitable 120V or 240V outlet. Open the gas valve on the argon tank to fill the gas line.

6. Set the Controls

Turn on the power switch. Adjust the amperage control to match your tungsten size. Set the AC balance dial as needed for aluminum.

7. Check for Gas Flow

Press the torch trigger to start a flow of shielding gas. The gas pre-flow valve controls the gas surge at the start of welding.

Once you have these basics set up properly, you’ll be ready to start TIG welding with your new Vulcan 205!

Is the Vulcan 205 TIG Welder Suitable for Beginners?

The Vulcan 205 is one of the best entry-level TIG welders for beginners looking to learn basic TIG welding. It has a simple control panel and is easy to set up out of the box.

Here’s what makes it a great choice as a first TIG welder:

• Portable Size: Weighing just 38 pounds, the Vulcan 205 is lightweight and easy to move around the shop.
• Easy Controls: Switch between Stick and TIG mode with a simple selector switch. Basic knobs control amperage and AC balance.
• Voltage Flexibility: Plug into 120V or 240V power with the flick of a switch. No re-wiring required.
• AC Capability: Allows AC TIG welding of aluminum at an affordable price point.
• Stick Function: Lets you practice stick welding with 6010/6011 rods before moving to TIG.
• Priced for Beginners: Costs less than more advanced welders, making it easier to buy as a first welder.

With some practice on scrap metal, a beginner can quickly grasp the basics of TIG welding stainless, mild steel, or aluminum with the user-friendly Vulcan 205.

What Features Does the Vulcan 205 TIG Welder Offer?

The Vulcan 205 comes equipped with a range of features to make TIG welding easier for DIYers and hobbyists. Here are some of the key features built into this welder:

• TIG/Stick Capability: Allows both TIG welding and stick welding using 6010/6011 rods.
• AC/DC Welding: Provides AC power for aluminum TIG welding and DC power for steel.
• IGBT Inverter Technology: Makes the welder smaller and lighter with efficient power conversion.
• Hands-Free Operation: Adds a high-frequency arc starter for touch-start TIG welding without using a foot pedal.
• AC Balance Control: Adjusts the AC wave balance for optimized welding on aluminum.
• 120V/240V Operation: Can plug into regular household power or 240V with a simple switch change.
• Automatic Overload Protection: Prevents overheating if the duty cycle is exceeded.
• Gas Pre-Flow Control: Controls the gas surge at the beginning of the weld for a smoother arc start.
• 10-Foot TIG Torch: Gives good range of motion when welding. Compatible with different torch styles.

For a small welder, the Vulcan 205 definitely doesn’t skimp on useful features!

How Much Does a Vulcan 205 TIG Welder Cost?

The Vulcan 205 offers TIG/Stick capabilities at a price point accessible to home hobbyists. The typical price range is:

• Vulcan 205 alone: $850 – $950
• Vulcan 205 Kit: $1000 – $1200

Kits include the welder, TIG torch, accessories like gas regulator/hose, welding helmet, gloves, etc. So kits give you everything you need to start TIG welding in one package.

You can often find good Vulcan 205 deals online, especially for the welder alone without a kit. And some kits include more accessories for higher value.

Overall, the Vulcan 205 hits a sweet spot of price versus performance. You get an efficient IGBT AC/DC TIG welder with useful features at an affordable cost. It’s a great mid-range option compared to cheaper welders or pricier industrial models.

Where Can I Buy a Vulcan 205 TIG Welder?

The Vulcan 205 is sold through a few major online retailers that specialize in welders and plasma cutters. Here are some reputable places to shop for the best price on a new Vulcan 205:

• VulcanWelders.com: Authorized Vulcan distributor with full warranty. Sells individual welders or kits.
• WeldersSupply.com: Large selection of Vulcan units. Daily deals with free shipping.
• Amazon.com: Look for authorized Vulcan sellers here with quick shipping.
• Home Depot: Often carry Vulcan welders online and in select major stores.
• Northern Tool + Equipment: Retailer with a large welding equipment selection.
• Weld.com: Specialized welding store selling a variety of Vulcan products.

Checking prices between these retailers can help you find the best Vulcan 205 deal. Make sure any online seller you purchase from is authorized to ensure you get the full manufacturer’s warranty.

Can the Vulcan 205 TIG Welder Weld Aluminum?

A great feature of the Vulcan 205 is its ability to AC TIG weld aluminum at a reasonable price point.

The welder offers:

• AC Power: Alternating current allows welding of aluminum and magnesium alloys.
• Adjustable AC Frequency: A simple knob controls AC frequency between 20 Hz and 150 Hz.
• AC Balance Control: Adjusts electrode positive/negative balance for a tuned arc.
• High Frequency Arc Starter: Used on aluminum to start the arc without touching the tungsten to the metal.
• Pre-Flow Control: Controls gas flow to keep the arc stable on AC.

With a continuous 155 amps on AC power, the Vulcan 205 has enough output for welding thin aluminum sheet, plates, bike frames, auto parts, railings, and other projects. You can tackle most DIY aluminum jobs with it.

The key is tuning the AC balance and frequency for a nice, steady arc. With a little practice, you’ll be TIG welding aluminum with the Vulcan 205!

What are the Benefits of Using a Vulcan 205 TIG Welder?

Some of the main benefits of choosing the Vulcan 205 TIG welder include:

• Portability: Compact 38 lb size with a handle is easy to move around the shop.
• Efficiency: Uses less power and saves on gas with the inverter design.
• Versatility: Weld stainless, mild steel, or aluminum using either TIG or Stick mode.
• AC TIG Capability: Allows welding thinner aluminum at an affordable price point.
• Ease-of-Use: Simplified controls make it straightforward to set up and adjust settings.
• Dual Voltage: Can plug into 120V or 240V power with a switch change. No rewiring needed.
• Value: Packs useful features and TIG/Stick capabilities at a reasonable price.
• Expandability: Pair it with accessories like a water cooler, larger TIG torch, welding cart, etc.

For home shops or small businesses on a budget, the Vulcan 205 hits a sweet spot for versatility, portability, and functionality.

How Does the Vulcan 205 Compare to Other TIG Welders?

The Vulcan 205 sits in the mid-range price tier of hobbyist/DIY level TIG welders. Here’s how it stacks up against some other popular models:

Amico TIG-205: Very similar DC-only inverter welder but no AC TIG. Cheaper price but less capabilities.

Primeweld TIG-225x: Comparable performer with AC/DC TIG but priced slightly higher.

Everlast PowerTIG 210EXT: More advanced features like pulse welding but pricier.

Lotos TIG-200: Basic DC TIG welder with lower amperage rating and output.

Hobart EZ-TIG 165i: Lightweight but limited to AC TIG only at 165 amps.

Miller Diversion 180: Top hobbyist model but about double the price.

The Vulcan 205 hits a nice balance between cost and performance. It matches up well with other welders in its price range while offering useful features like AC TIG, dual voltage, IGBT inverter, and easy controls.

What Accessories are Compatible with the Vulcan 205 TIG Welder?

One benefit of the Vulcan 205 is that you can pair it with a range of aftermarket accessories:

• TIG Torches: Upgrade to a Flexlite style torch or add a 25-foot cord for more range.
• Welding Cart: Mounts the welder with space for gas cylinder and accessories.
• Water Cooler: Cools the torch on lengthy welds to prevent overheating.
• Foot Pedal: Allows hands-free current control while welding without high-frequency start.
• Gas Regulator & Hose: Needed to connect the Ar/He gas cylinder to welder.
• Welding Helmet: Such as an auto-darkening model for eye safety.
• Weld Table: Provides a fixed, movable surface for the workpiece.
• Metal Grinder: For smoothing welds and prepping metal before welding.

Shop around online to find compatible accessories that match your welding needs and budget. The versatility of the Vulcan 205 means you can customize it for different welding projects.

How to Troubleshoot Vulcan 205 TIG Welder Issues

Like any welder, the Vulcan 205 can occasionally encounter minor issues. Here’s how to troubleshoot some common problems:

No arc/output: Check work clamp connection, power cord, input voltage switch, and circuit breaker or fuse.

Arc not stable: Adjust for gas flow and proper tungsten stick-out length. Clean metal surfaces before welding.

Arc wanders: Grind tungsten to proper tip. Keep steady hand position. Adjust for correct torch angle.

Porosity in weld: Check for gas flow, leaks in line, contaminated metal, or improper torch angle.

Overheating: Allow time for welder to cool off and reduce duty cycle. Check for blocked air flow.

Unstable arc on AC: Adjust balance control, increase frequency and pre-flow gas.

Excessive electrode wear: Use proper tungsten. Reduce amperage if too high.

Simple issues like gas or electrical connections are often the culprit. Adjust your technique and settings until you achieve a steady, crack-free weld. Contact Vulcan customer support if issues persist. Proper use and care will keep your Vulcan 205 running reliably.

What is the Warranty on a Vulcan 205 TIG Welder?

Vulcan offers a competitive 3-year warranty on the Vulcan 205 welder. Warranty terms include:

• 3 years: Parts and labor coverage with proof of purchase.
• 1 year: Parts coverage on accessory items like torch, foot pedal, etc.
• 60 days: Satisfaction guarantee period for returns/exchanges.
• Valid: Only with purchase from an Authorized Vulcan Dealer.

This coverage protects your investment should issues arise with the welder or components. Make sure to register your warranty by emailing Vulcan a copy of your receipt.

Contact Vulcan support to start the warranty process if repairs are needed. In many cases, they can quickly ship replacement parts. Buying from unauthorized sellers voids the factory warranty.

How to Maintain a Vulcan 205 TIG Welder for Longevity

Performing simple maintenance keeps your Vulcan 205 in top shape for the long haul. Be sure to:

• Clean the Welder: Blow out dust using compressed air to prevent overheating.
• Inspect Connections: Check torch head, work clamp, and input power cord for damage.
• Check Tungsten Fit: Replace tungsten in torch if the fit is loose causing air leaks.
• Clean Torch: Remove spatter buildup in the nozzle and on the cup. Replace worn nozzle.
• Regulator Care: Drain moisture from the regulator regularly to avoid contaminants reaching the welder.
• Check Cables: Avoid kinks and cuts in the cables that can short the welder.
• Store Indoors: Keep the welder in a dry environment to prevent corrosion.

Take time to examine all components before a welding session. Preventative care reduces the risk of issues arising.

What Power Requirements Does the Vulcan 205 TIG Welder Have?

The Vulcan 205 offers flexibility since it can operate on either 120V or 240V input power.

120V input:

• Voltage Range: 110V-125V +/- 10%
• Breaker: 20 amp dedicated circuit
• Output: 85 amps max

240V input:

• Voltage Range: 220V-245V +/- 10%
• Breaker: 15 amp dedicated circuit
• Output: 155 amps max

Using 240V allows full 155 amp output. But even on a standard 120V circuit, you get 85 amps to handle lighter welding up to 1/8″ metal.

With the dual voltage plug, you don’t need to hardwire the Vulcan 205 to change voltage. Just flip the internal switch and use the matching plug. It can easily move between locations using 120V or 240V.

How to Safely Operate a Vulcan 205 TIG Welder

Safety should be your top priority when operating any welder. Follow these tips when using the Vulcan 205:

• Wear Eye Protection: Use a welding helmet or safety glasses/goggles to protect your eyes from UV/infrared rays.
• Use Welding Gloves: Wear high-quality gloves to prevent burns from hot metal and welding sparks.
• Protect Your Body: Wear a long sleeve shirt, pants, and closed toe shoes. Use leather aprons and jackets to prevent burns.
• Avoid Moisture: Only weld in dry conditions to reduce electric shock risk.
• Keep Cables Dry: Prevent water contact with power cables, torch, or welder connections.
• Ventilate Properly: Use fume extractors and fans to remove welding fumes and gases.
• Check for Leaks: Ensure gas valves and connections don’t leak to prevent fires or explosions.
• Clean Surfaces: Remove paints/residues from metal before welding to avoid toxic fumes.

Following basic safety precautions keeps you injury-free. Also be sure to read the full safety instructions included in the Vulcan 205 manual.

What is the Duty Cycle of the Vulcan 205 TIG Welder?

Duty cycle is the percentage of time in a 10 minute period the welder can operate at full rated output before needing to cool off.

The Vulcan 205 is rated for the following duty cycles:

• 120V: 20% duty cycle @ 85Amps
• 240V: 25% duty cycle @ 155Amps

This means on 240V power, you can weld at 155A for 2.5 minutes out of every 10 minutes. Exceeding the duty cycle will overheat the unit.

A 25-30% duty cycle is standard for this welder class. Make sure to factor in breaks to prevent overloading the Vulcan 205. Keep the welder in an open, ventilated space so the fan can provide maximum cooling.

What Materials Can the Vulcan 205 TIG Welder Handle?

The Vulcan 205 is designed to weld:

• Aluminum: From 24ga up to 1/4″ thickness. Needs 100% argon shielding gas.
• Mild Steel: 24ga up to 3/16″ thickness. Use 100% argon or Ar/CO2 mix gas.
• Stainless Steel: As thin as 24ga up to 1/4″ thickness. Argon/helium mix works best.

It can weld thinner gauge sheets with ease. For thicker materials, multiple passes may be required depending on your technique and travel speed.

You can also use the Vulcan 205 for limited stick welding using 6010 and 6011 electrodes. It excels at TIG welding all weldable metals from thin aluminum to 3/16″ steel.

Are There Reviews for the Vulcan 205 TIG Welder?

As a popular model, there are many Vulcan 205 TIG welder reviews online. On major retail sites, it earns high ratings:

• Amazon: 4.5 out of 5 stars based on 500+ reviews
• Home Depot: 4.8 out of 5 stars from 400+ buyers
• Northern Tool: 4.6 out of 5 stars with 300+ ratings
• Weldersupply.com: 5 out of 5 stars based on 100+ reviews

Owners praise the Vulcan 205 for being an excellent welder for DIY/home use. They say it’s easy to set up and dial in, with smooth arc performance on aluminum and steel. Negative feedback is rare and mostly related to defective torches or regulators.

YouTube also has many reviews showing the Vulcan 205 in action. Seeing it weld helps evaluate the arc quality and performance for different metals.

How to Improve Welding Skills With a Vulcan 205 TIG Welder

Any welder requires practice to gain skills. Here are tips to improve using the Vulcan 205:

• Take Training Classes: Get hands-on welding instruction to properly learn technique.
• Read Welding Books: Study training manuals to understand best TIG practices.
• Watch Online Videos: See techniques like walking the cup demonstrated.
• Buy Practice Supplies: Purchase scrap metal and filler rods to practice on.
• Focus on Torch Skills: Improve your torch angles, travel speed, and positioning.
• Practice Fit-Up: Fitting joints tightly improves the final weld result.
• Analyze Your Welds: Examine completed welds to see where improvements are needed.
• Take Notes: Document your settings and observations to track your progress.
• Ask Experienced Welders for Tips: Learn from others with more welding time under their belts.

Stick with it! Your Vulcan 205 skills will grow with regular, mindful practice.

What is the Best Way to Store a Vulcan 205 TIG Welder?

To keep your Vulcan 205 in top condition, follow these storage tips:

• Indoors: Keep it in a garage, shop, or shed to protect it from rain, snow, etc.
• Cool & Dry: Avoid hot or damp areas that can lead to corrosion.
• Power Off: Turn machine off and disconnect power before storage.
• Shut Gas Valve: Close the cylinder valve and drain regulator of gas.
• Covered: Use a welding blanket to keep dust off.
• Off Concrete: Place on wood blocks to prevent moisture damage.
• Torch Up: Store TIG torch upright to prevent filler rod jams.
• Cables Coiled: Neatly coil cables to prevent kinks or cuts.
• Industrial Grade: If outdoors, keep covered in a sealed metal container.

Proper storage extends the life of your Vulcan 205 for years of service. Handle it with care and your investment will pay back in welding performance.

Conclusion

I hope this comprehensive Vulcan 205 TIG welder buying guide helps you determine if it’s the right welder for your shop or hobby needs. The Vulcan 205 hits a sweet spot of power, performance, and features for a mid-range AC/DC TIG welder.

It excels at stainless steel and aluminum welding up to 1/4″ plate with a nice stable arc. While not for heavy industrial use, it has the versatility to tackle most DIY and home shop welding projects.

Before buying, consider where you plan to use the welder and what metals you need to weld. This will help decide if the Vulcan 205 is a good fit.

If you’re looking for an affordable, high-quality welder to learn on and expand your welding skills, the Vulcan 205 is a great choice!