Best Engine Driven Welder Generators

Engine driven welder/generators are machines that are primarily used to provide generator power and stick welding capability. They’re cost effective and a great machine for farm and ranch that can be mounted on the back of a trailer or wheeled around for extra portability. More expensive models also have the option to be used for MIG/TIG welding with additional equipment.

This guide compares the best welder/generators on the market at a range of different sizes, prices and specifications.

Welder/Generator Comparison Chart

WelderImageMax AmpFuelCon PowerProcessAC
DC
lbPriceMore
Lincoln Bulldog 5500Lincoln Bulldog 5500 Welder Generator140AGas4000WStickAC198$$
Review
Hobart Champion 145
medal Best portable
Hobart Champion 145 Welder Generator145AGas4000WStick/
DC TIG
DC222$
Review
Miller Fusion 160Miller Fusion 160 Welder Generator160AGas6200WStick/
DC TIG
DC242$$$$
Review
Lincoln Outback 185Lincoln Outback 185 Engine Driven Welder Generator185AGas5200WStick/
DC TIG
DC295$$$$
Review
Klutch 7500K
medal Great value
Klutch 7500K Welder Generator185AGas6000WStick/
DC TIG
DC308$$
Review
Miller Blue Star 185Miller Blue Star 185195AGas6200WStick/
DC TIG
DC296$$$$
Review
Hobart Champion Elite 225
medal Best all-round
Hobart Champion Elite 225 Welder Generator225AGas9500WStick/
DC TIG
DC490$$$
Review
Miller Bobcat 225Miller Bobcat 225225AGas9500WStick/
TIG/
MIG*/Flux*
AC
DC
485$$$$$
Review
Lincoln 225 EagleLincoln 225 Eagle 10000225AGas9000WStick/
DC TIG/
MIG*/Flux*
DC233$$$$
Review
Lincoln Ranger 250Lincoln Ranger 250250AGas10000WStick/
TIG/
MIG*/Flux*
AC
DC
574$$$$$
Review
Hobart Champion Elite 260Hobart Champion Elite 260260AGas9500WStick/
DC TIG
DC523$$$$
Review
Miller Bobcat 260Miller Bobcat 260260AGas**9500WStick/
TIG/
MIG*/Flux*
AC
DC
501$$$$$
Review
Miller Trailblazer 325Miller Trailblazer 325 Welder Generator325AGas**10500WStick/
DC TIG/
MIG*/Flux*
DC460$$$$$$
Review
*Additional wire feeder required
**Diesel model also available

Best Welder/Generators on The Market

1. Hobart Champion Elite 225

medal Best all-round

Hobart Champion Elite 225 Welder Generator
Power:4.5 out of 5 stars (4.5 / 5)
Build:5 out of 5 stars (5.0 / 5)
Performance:5 out of 5 stars (5.0 / 5)
Features:4.5 out of 5 stars (4.5 / 5)
Portability:4 out of 5 stars (4.0 / 5)
Price:4.5 out of 5 stars (4.5 / 5)
Average:4.6 out of 5 stars (4.6 / 5)

The Champion Elite 225 is the upgrade from the Champion 145 and is a really solid machine with a great generator. The tank is 12 gallons which is twice as big as the 145, it’s more than twice as heavy and has a Kohler 2 cylinder engine with a huge 11000-watt surge power. It’s also approximately twice the price but still pretty affordable at around $3000 and is incredible value for money.

It’s very similar to the Miller Bobcat 225 (Miller own Hobart) but much cheaper and without some key features such as remote start and wire feeder capability. You can’t wire feed straight off the unit but it does have a 50A 220V plug on the front where you can plug in your MIG welder so you can simultaneously have MIG and Stick running at the same time as well as another tool in the 120V plug. The receptacle package includes 1 6-50R 250V, 14-50R 250V and 2 115V 20A Duplex GFCI receptacles, so it just beats the Lincoln Eagle 1000 which has 2two 120V receptacles and one 120/240V 14-50R. This machine performs great as a DC welder and can run 5/32″ much easier than the Champion 145 and will burn them all day long for welding 1/2″ steel. It’s a Hobart quality machine with power so you’re going to get great performance for your welds and the duty cycle is 100% @ 225A.

A few extra features which are pretty cool is the auto idle to help save on fuel, electric start, no tools oil change, and digital hour meter to help schedule servicing (every 100 hours of use). Overall this is a professional quality machine at an affordable price and definitely worth considering.

Specifications

Brand Hobart
Model Champion Elite 225
Process Type DC Stick/DC TIG
Amperage Range 40-225A
Duty Cycle 100% @ 225A
Engine Kohler CH730
Continuous Power 9500W
Peak Power 11000W
Engine RPM 3600 (2400 Idle)
Fuel Gasoline
Tank Size 12gal
Weight 490lb
Warranty Hobart 3 Year
Full specs Specifications

Pros

  • Kohler 2 cylinder engine
  • Reliable machine
  • 12 Gallon fuel tank
  • 11000-watt generator
  • Auto Idle
  • Great value for money
  • Comfortably runs 5/32
  • 4 receptacles
  • Can simultaneously run 220V MIG

Cons

  • Not portable
  • No remote start

2. Lincoln 225 Eagle 10000 Plus

Lincoln 225 Eagle 10000
Power:4.5 out of 5 stars (4.5 / 5)
Build:5 out of 5 stars (5.0 / 5)
Performance:5 out of 5 stars (5.0 / 5)
Features:4.5 out of 5 stars (4.5 / 5)
Portability:4 out of 5 stars (4.0 / 5)
Price:4.5 out of 5 stars (4.5 / 5)
Average:4.6 out of 5 stars (4.6 / 5)

Lincoln make quality welders and this is pretty much the same unit as the more expensive Lincoln Ranger 225 but quite a bit cheaper which is why we’ve included this model. Lincoln state this unit is more designed for consumer use not industrial use, but there isn’t much difference between them other than that the Ranger 225 offers CC/CV whereas this Eagle 10,000 only offers CC welding, so it is less well suited for using with a wire feeder.

It’s a bit more expensive that the Champion Elite 225, but it’s still great value for money for a Lincoln product at under $4000. It also only has 40% duty cycle @ 225A vs 100% for the Miller and Hobart 225A machines but handles 5/32 electrodes with ease. The standout difference with the Champion Elite is that you can use a wire feeder with this for MIG/TIG/Flux.

The engine is a quality 23HP air-cooler Kohler 2-cylinder gasoline engine with a 12-gal fuel tank and usage rate of just 1.5 gallons/hour. You can also simultaneously use generator power whilst welding, with up to 6000 watts when welding at 90A and 3950 watts at 145A, which is enough for most power tools.

The interface is nice to use with fine adjustment to dial in the specific controls for your application and there are three receptacles on the front. Two 120V duplex receptacles that deliver up to 40 Amps and a single 120V/240V full-KVA receptacle that delivers up to 38 Amps. Overall it’s a quality welder that you can’t go wrong with.

Specifications

Brand Lincoln Electric
Model Eagle 10,000 Plus
Process Type DC Stick/DC TIG/MIG/FCAW
Amperage Range 50-225A
Duty Cycle 100% @ 210A
Engine Kohler CH23S
Continuous Power 9000W
Peak Power 10500W
Engine RPM 3600 (2200 idle)
Fuel Gasoline
Tank Size 12gal
Weight 514lb
Warranty 3 Year
Full specs Specifications

Pros

  • Electric start
  • Kohler 2 cylinder engine
  • Reliable machine
  • 12 Gallon fuel tank
  • 11000-watt generator
  • Auto Idle
  • Great value for money
  • Comfortably runs 5/32
  • 3 receptacles
  • Capable of using with wire feeder
  • 3-year Lincoln Electric warranty

Cons

  • Heavy
  • More expensive than champion elite
  • No remote start

3. Hobart Champion 145 Stick Welder/Generator 500563

 medal Best under $2000medal Best portable welder generator

Hobart Champion 145 Welder Generator
Power:4 out of 5 stars (4.0 / 5)
Build:5 out of 5 stars (5.0 / 5)
Performance:4.5 out of 5 stars (4.5 / 5)
Features:4 out of 5 stars (4.0 / 5)
Portability:5 out of 5 stars (5.0 / 5)
Price:5 out of 5 stars (5.0 / 5)
Average:4.6 out of 5 stars (4.6 / 5)

The Hobart Champion 145 is the perfect entry level portable welder generator. It’s cost effective, portable and lighter duty. It comes with running gear and it’s small enough to move around without too much difficulty which makes it an excellent choice for light agricultural welding. It’s the only machine that’s available for under $2000, so if you want an engine driven welder and don’t have $3000-$4000 to spend on one, this is a great option. 

It has 4500 Watt surge power and 4000 Watt continuous, which is lower than most other machines, but this should be fine for most hobbyists. The main downsides are that it doesn’t weld and work as a generator at the same time very well. You’re better off using it as either one at a time. It’s pretty fuel efficient but there’s no auto idle and there’s no electric start which is a bit annoying, but for the price it’s hard to complain.

As a welder it’s a dependable unit that performs well.  It will welds steel up to 1/4″ and can just about manage 5/32″ 7018s but will get the best results with 1/8″ 7018 and 5/32″ 6011 or 6013. You can also plug in a 220V MIG unit if you want to MIG weld.

Overall this is a pretty basic machine but it’s reliable and will do all the essentials a hobbyist requires but without a few extra luxuries. The price for this is great and if you’re on a budget looking for your first engine driven welder this is probably the one for you. 

Specifications

Brand Hobart
Model Champion 145
Process Type DC Stick/DC TIG
Amperage Range 40-145A
Duty Cycle 30% @ 130A
Engine Briggs & Stratton 1450
Continuous Power 4000W
Peak Power 4500W
Engine RPM 3600
Fuel Gasoline
Tank Size 6.25gal
Weight 222lb
Warranty Hobart 3 Year
Full specs Specifications

Pros

  • Use up to 5/32 electrodes
  • Portable at 222lbs
  • Running gear built in
  • Large muffler for quiet operation
  • Excellent price
  • Reliable machine

Cons

  • Low power
  • No auto idle
  • No electric start

4. Hobart Champion Elite 260 Stick Welder/Generator 500577

Hobart Champion Elite 260
Power:5 out of 5 stars (5.0 / 5)
Build:5 out of 5 stars (5.0 / 5)
Performance:5 out of 5 stars (5.0 / 5)
Features:4.5 out of 5 stars (4.5 / 5)
Portability:4 out of 5 stars (4.0 / 5)
Price:4 out of 5 stars (4.0 / 5)
Average:4.6 out of 5 stars (4.6 / 5)

The Champion Elite 260 is basically the big brother of the Champion Elite 225 and has a lot of the same specifications but packs more welding power. The engine is exactly the same as the 225 and you get the same generator power and features. The key difference with this machine is that you get a bit extra welding power for a few hundred dollars extra. This welder will weld from 40-260A with 100% duty cycle @260A. It’s a lot cheaper than the Bobcat 260 but with quite similar specifications (again, Miller own Hobart). 

The generator power is available while welding and it comes with the same 1 6-50R 250V, 14-50R 250V and 2 115V 20A Duplex GFCI receptacles at the Champion Elite 225. Overall this is a great machine if you want a bit extra power to run 3/16 electrodes. 

Specifications

Brand Hobart
Model Champion Elite 260
Process Type DC Stick/DC TIG
Amperage Range 40-260A
Duty Cycle 100% @ 260A
Engine Kohler CH730
Continuous Power 9500W
Peak Power 11000W
Engine RPM 3600 (2400 Idle)
Fuel Gasoline
Tank Size 12gal
Weight 523lb
Warranty Hobart 3 Year
Full specs Specifications

Pros

  • Kohler 2 cylinder engine
  • Reliable machine
  • 12 Gallon fuel tank
  • 11000-watt generator
  • Auto Idle
  • Great value for money
  • Comfortably runs 3/16
  • Can simultaneously run 220V MIG

Cons

  • More expensive than the 225
  • Not portable
  • No remote start

5. Klutch 7500K 185 Arc Welder/Generator

medal Best for the money

Klutch 7500K Welder Generator
Power:4.5 out of 5 stars (4.5 / 5)
Build:4.5 out of 5 stars (4.5 / 5)
Performance:4.5 out of 5 stars (4.5 / 5)
Features:4.5 out of 5 stars (4.5 / 5)
Portability:4.5 out of 5 stars (4.5 / 5)
Price:4.5 out of 5 stars (4.5 / 5)
Average:4.5 out of 5 stars (4.5 / 5)

This welder/generator from klutch is a great all-round machine that does a amazing job of balancing generator power, welding capabilities and portability at a really affordable price. 

It’s not the greatest machine on fuel. There’s no auto-idle and the fuel tank is only 5 gallons. This is a bit smaller than other welder/generators of similar class, but you can get up to 8 hours of operation on a single fill. For power you can get 6000 watts continuous power, which you’re unlikely to find on another welder/generator at this price. It also has 4 120V receptacles and one 240V receptacle on the front, so you can plug in a range of power tools and there’s plenty of power to run appliances when welding.

As a welder it actually welds really well and can handle 5/32 electrodes with rated output 30% @ 185A and 100% @ 100A. What’s also great about this is the wheelbarrow style design which massively helps with portability. Overall this isn’t much more expensive than the Hobart Champion 145 but you do get a bit more power, so it’s definitely one to look at if you want a portable machine on a budget.

Specifications

Brand Klutch
Model 7500K
Process Type DC Stick/DC TIG
Amperage Range 60-185A
Duty Cycle 30% @ 185A
Engine Kohler CH440
Continuous Power 6000W
Peak Power 6600W
Engine RPM 3600
Fuel Gasoline
Tank Size 5gal
Weight 308lb
Warranty 3 Year
Full specs Specifications

Pros

  • Great value for money
  • Portable wheelbarrow style cart
  • Kohler Engine
  • 5 receptacles
  • 3 year warranty
  • Handles 5/32 electrodes

Cons

  • Recoil start
  • Only 5gal tank size
  • No auto idle

6. Miller Trailblazer 325

medal Best professional welder/generator

Miller Trailblazer 325 Welder Generator
Power:5 out of 5 stars (5.0 / 5)
Build:5 out of 5 stars (5.0 / 5)
Performance:5 out of 5 stars (5.0 / 5)
Features:5 out of 5 stars (5.0 / 5)
Portability:4 out of 5 stars (4.0 / 5)
Price:3 out of 5 stars (3.0 / 5)
Average:4.5 out of 5 stars (4.5 / 5)

This machine is the elite option for any professional welding contractor looking for a top of the range welder/generator. The machine is really expensive but it’s an absolute powerhouse with some great features.

Firstly, it’s great for fuel efficiency, which not only saves money but also saves time having to refuel. There’s an Electronic fuel injection (EFI) option to give you more reliable starts and up to 42% more fuel efficient. The auto-speed technology automatically adjusts the engine RPM so that it doesn’t use more energy that it needs to, which saves fuel and reduces noise and pollution. There’s also an auto idle excel power to deliver 2400 watts of 120V inverter based power when on idle mode. You can also get full wireless control of the machine to turn the machine on and off, adjust parameters and more to save you time moving back and forth from the machine.

As a welder it’s a quality machine that is versatile and offers an amazing 100% rated output @ 325A and the ability to attach a wire feeder for MIG and FCAW on CV. It’s also available in diesel as well as gas.

Specifications

Brand Miller
Model Trailblazer 325
Process Type DC Stick/DC TIG/MIG*/FCAW*
Amperage Range 20-325A
Duty Cycle 100% @ 325A
Engine Kohler CH730
Continuous Power 10500W
Peak Power 12000W
Engine RPM 3600
Fuel Gasoline**
Tank Size 12gal
Weight 460lb
Warranty Miller 3 Year
Full specs Specifications

Pros

  • Great for fuel savings
  • Reduced sound
  • Electronic fuel injection
  • Auto speed technology
  • Wireless control
  • Diesel or gas
  • Super powerful
  • Quality, reliable machine
  • 3 receptacles
  • Compatible with wire feeder

Cons

  • Expensive
  • Not portable (although light for its power)

7. Miller Bobcat 260

Miller Bobcat 260
Power:5 out of 5 stars (5.0 / 5)
Build:5 out of 5 stars (5.0 / 5)
Performance:5 out of 5 stars (5.0 / 5)
Features:5 out of 5 stars (5.0 / 5)
Portability:4 out of 5 stars (4.0 / 5)
Price:3.5 out of 5 stars (3.5 / 5)
Average:4.6 out of 5 stars (4.6 / 5)

The Bobcat 260 is a dream welder/generator for most farm/ranch workers due to its amazing features and specifications, although it comes at a quite hefty price. As a generator it tickets all the boxes with a Kohler 2 cylinder engine, 9500 watts continuous power and 11,000 watts peak power, or 10,500 watts continuous and 12,000 watts peak for the Electric fuel injection (EFI model). The EFI model allows for better fuel efficiency, easy starts, fewer emissions and more generator power. It is also a fuel efficient machine with auto idle to reduce fuel wastage and remote start so you can operate the machine from a distance. 

It’s a versatile machine as a welder, it can weld CC/CV, AC/DC and can is compatible with a wire feeder for MIG and Flux-cored welding. The rated output for DC Stick is 100% @ 260A and you’ll be able to burn 3/16 electrodes all day. It’s also available with diesel. Overall this welder/generator has everything you’d every want and more on for farm/ranch, just remember it comes at a price. 

Specifications

Brand Miller
Model Bobcat 260
Process Type AC&DC Stick/DC TIG/MIG*/FCAW*
Amperage Range 40-260A
Duty Cycle 100% @ 225A
Engine Kohler CH730
Continuous Power 9500W
Peak Power 11000W
Engine RPM 3600 (2300 idle)
Fuel Gasoline**
Tank Size 12gal
Weight 501lb
Warranty Miller 3 Year
Full specs Specifications

Pros

  • Remote start
  • Wire feeder compatible
  • Capable of AC&DC Stick
  • Kohler 2 cylinder engine
  • Reliable machine
  • 12 Gallon fuel tank
  • 11000-watt generator
  • Auto Idle
  • Comfortably runs 3/16
  • 3 receptacles
  • Gas or Diesel

Cons

  • Expensive

8. Miller Bobcat 225

Miller Bobcat 225
Power:4.5 out of 5 stars (4.5 / 5)
Build:5 out of 5 stars (5.0 / 5)
Performance:5 out of 5 stars (5.0 / 5)
Features:5 out of 5 stars (5.0 / 5)
Portability:4 out of 5 stars (4.0 / 5)
Price:3.5 out of 5 stars (3.5 / 5)
Average:4.5 out of 5 stars (4.5 / 5)

The Bobcat 225 is really a great 225A machine, although it is the most expensive on the market which might put you off unless you love Miller. One of the main features of this vs the Hobart and Lincoln 225s is the remote start feature so you can control  your machine over 300ft away without having to walk back to it. This can actually save you quite a bit of money in fuel savings over time, especially if you’re welding at a long distance from the machine.

This also has 100% duty cycle @ 225A vs 40% for the Lincoln Eagle and it offers CC/CV and AC Stick up to 160A. It can run a wire feeder unlike the Hobart 225 and is about 40lb lighter than the Lincoln 225. Other than that there aren’t that many differences. Hobart, Lincoln and Miller are all well built, perform well and have similar specifications.

Overall this is a immensely well build machine with generator power that’s great for farm/ranch. Is it worth the extra bucks? Well that’s up to you, if you want the best 225 unit that money can buy then this is our pick, but this unit isn’t all that different from the Lincoln Eagle and Hobart Champion Elite which are both similar machines and a lot cheaper. 

Specifications

Brand Miller
Model Bobcat 225
Process Type AC&DC Stick/DC TIG/MIG*/FCAW*
Amperage Range 40-225A
Duty Cycle 100% @ 225A
Engine Kohler CH730
Continuous Power 9500W
Peak Power 11000W
Engine RPM 23.5HP@3600
Fuel Gasoline
Tank Size 12gal
Weight 485lb
Warranty 3 Year
Full specs Specifications

Pros

  • Remote start
  • Wire feeder compatible
  • Capable of AC&DC Stick
  • Kohler 2 cylinder engine
  • Reliable machine
  • 12 Gallon fuel tank
  • 11000-watt generator
  • Auto Idle
  • Comfortably runs 5/32
  • 3 receptacles

Cons

  • Expensive
  • Not portable

9. Lincoln Electric Ranger 250 GXT

Lincoln Ranger 250
Power:5 out of 5 stars (5.0 / 5)
Build:5 out of 5 stars (5.0 / 5)
Performance:5 out of 5 stars (5.0 / 5)
Features:4.5 out of 5 stars (4.5 / 5)
Portability:4 out of 5 stars (4.0 / 5)
Price:3.5 out of 5 stars (3.5 / 5)
Average:4.5 out of 5 stars (4.5 / 5)

The Lincoln Ranger is an absolutely solid piece of kit that’s designed to stand up to industrial use. With the Ranger 250 you can weld AC and DC for a broader range of stick electrodes and the ability to weld magnetized steel. It’s also capatable of AC TIG, MIG and Flux Cored with optional equipment. It has a large top fuel neck for easy refuelling. The machine does have auto idle to help save on fuel, but not some of the other fuel saving features of the Miller Bobcat range.  Overall it’s a quality and well built machine that you’d expect from Lincoln, with parts easily accessible for maintenance if required and removable side doors. 

Specifications

Brand Lincoln Electric
Model Ranger 250
Process Type DC Stick/DC TIG
Amperage Range 50-250A
Duty Cycle 100% @ 250A
Engine Kohler CH730
Continuous Power 10000W
Peak Power 11000W
Engine RPM 3600(2400 idle)
Fuel Gasoline
Tank Size 12gal
Weight 574lb
Warranty 3 Year
Full specs Specifications

Pros

  • Electric start
  • Versatile AC/DC machine
  • Kohler 2 cylinder engine
  • Reliable machine
  • 12 Gallon fuel tank
  • 11000-watt generator
  • Auto Idle
  • Great value for money
  • Comfortably runs 3/16 electrodes
  • 3 receptacles
  • Capable of using with wire feeder
  • 3-year Lincoln Electric warranty

Cons

  • Expensive
  • Heavy

10. Lincoln Outback 185

Lincoln Outback 185 Engine Driven Welder Generator
Power:4.5 out of 5 stars (4.5 / 5)
Build:5 out of 5 stars (5.0 / 5)
Performance:4.5 out of 5 stars (4.5 / 5)
Features:4.5 out of 5 stars (4.5 / 5)
Portability:4.5 out of 5 stars (4.5 / 5)
Price:4 out of 5 stars (4.0 / 5)
Average:4.5 out of 5 stars (4.5 / 5)

The Outback 185 is a great 185A DC stick welder/generator. It’s designed to have portability at under 300lbs with low lift grab bars to make it easier to carry and add some extra protection against damage.

The user interface is easy to use and all the controls including electric start are on the front of the machine. It also has 3 receptacles on the front to plug in your power tools, lights or a 140A or 180A MIG welder if you want to simultaneously MIG weld from this machine.

It has a larger fuel fill reopening than the Milller 185 and a slightly larger fuel tank (6.8 vs 6.25ga) so you can get about about 10% extra fuel. It also has auto idle to help save on fuel. The duty cycle is lower than the Miller 185 but it still performs great and will weld up to 5/32 electrodes.

Specifications

Brand Lincoln Electric
Model Outback 185
Process Type DC Stick/DC TIG
Amperage Range 50-185A
Duty Cycle 20% @ 150A
Engine Kohler CH440
Continuous Power 5200W
Peak Power 5700W
Engine RPM 3600
Fuel Gasoline
Tank Size 6.8gal
Weight 295lb
Warranty 3 Year
Full specs Specifications

Pros

  • Electric start
  • Kohler engine
  • Low-lift bars for portability
  • Reliable machine
  • Larger fuel tank than Miller 185
  • Auto Idle
  • Welds up to 5/32 electrodes
  • 3 receptacles
  • 3-year Lincoln Electric warranty

Cons

  • Expensive
  • Low duty cycle
  • One cylinder engine

11. Miller Blue Star 185

Miller Blue Star 185
Power:4.5 out of 5 stars (4.5 / 5)
Build:5 out of 5 stars (5.0 / 5)
Performance:5 out of 5 stars (5.0 / 5)
Features:4.5 out of 5 stars (4.5 / 5)
Portability:4.5 out of 5 stars (4.5 / 5)
Price:3.5 out of 5 stars (3.5 / 5)
Average:4.5 out of 5 stars (4.5 / 5)

The Miller Blue Star 185 is a top quality welder/generator. It’s available for a similar price to the Hobart Champion Elite 225 but it only has 6.25 gallon fuel and 6200-watt continuous power.  Under a continuous load of 3,000 watts of generator, the Blue Star 185 will run for about 7.5 hours. On the front are 2 120 VAC GFCI receptacles and one 240 VAC receptacle to plug in your appliances.

As a welder it can use up to 5/32 electrodes and has a rated output of 100% @ 150A, which is better than the Lincoln 185. At 296lbs it’s not too heavy, but it doesn’t have the low-lift bars or running gear of similar class machines to help with portability. With Miller you know you’re getting something that’s super well built. Overall this has a good balance of power and portability that will suit certain hobby/farm users looking for these parameters.

Specifications

Brand Miller
Model Blue Star 185
Process Type DC Stick/DC TIG
Amperage Range 60-195A
Duty Cycle 20% @ 195A
Engine Kohler CH440
Continuous Power 6200W
Peak Power 6500W
Engine RPM 3600 (2500 Idle)
Fuel Gasoline
Tank Size 6.25gal
Weight 296lb
Warranty Miller 3 Year
Full specs Specifications

Pros

  • Electric start
  • Kohler engine
  • Reliable machine
  • Auto Idle
  • Welds up to 5/32 electrodes
  • 3 receptacles
  • 3-year Miller warranty

Cons

  • One cylinder engine
  • Running gear/lift bars not included
  • Smaller tank than Lincoln
  • Expensive

12. Miller Fusion 160

Miller Fusion 160 Welder Generator
Power:4 out of 5 stars (4.0 / 5)
Build:5 out of 5 stars (5.0 / 5)
Performance:4.5 out of 5 stars (4.5 / 5)
Features:4.5 out of 5 stars (4.5 / 5)
Portability:4.5 out of 5 stars (4.5 / 5)
Price:3.5 out of 5 stars (3.5 / 5)
Average:4.3 out of 5 stars (4.3 / 5)

The main feature of the Miller Fusion 160 is that it offers the revolutionary “Power Shift” technology whereby the generator can be used on gasoline or 120/240V utility power gasoline powered in the field or switch to outlet power when moving indoors. As a welder it’s capable of DC stick welding. It’s more portable that the Miller 185 but actually offers a bit more generator power with up to 6500 watts peak power. To be honest, for an entry level welder/generator we’d probably opt for the Hobart 145 and then look at upgrading to a Champion Elite or a Bobcat, but if this is going to give you everything you need or you really think the power shift is going to come in handy then go for this.

Specifications

Brand Miller
Model Fusion 160
Process Type DC Stick/DC TIG
Amperage Range 30-160A
Duty Cycle 20% @ 160A
Engine Kohler CH440
Continuous Power 6200W
Peak Power 6500W
Engine RPM 3750 (2500 Idle)
Fuel Gasoline
Tank Size 6.25gal
Weight 242lb
Warranty Miller 3 Year
Full specs Specifications

Pros

  • Electric start
  • Kohler engine
  • Can plug into power outlet
  • Reliable machine
  • Auto Idle
  • Welds up to 5/32 electrodes
  • 3 receptacles
  • 3-year Miller warranty
  • Relatively lightweight

Cons

  • One cylinder engine
  • Running gear/lift bars not included
  • Expensive

13. Lincoln 140 Bulldog 5500

Lincoln Bulldog 5500 Welder Generator
Power:4 out of 5 stars (4.0 / 5)
Build:5 out of 5 stars (5.0 / 5)
Performance:4.5 out of 5 stars (4.5 / 5)
Features:4 out of 5 stars (4.0 / 5)
Portability:5 out of 5 stars (5.0 / 5)
Price:4.5 out of 5 stars (4.5 / 5)
Average:4.5 out of 5 stars (4.5 / 5)

One of the most noticeable things about this welder/generator is that it welds with AC only. We tend to prefer DC because it offers higher penetration, less spatter and easier starts. However, some people prefer AC stick welding. AC stick allows you to weld on magnetised steel, so if you want to weld machines that are magnetized then an AC unit is perfect. AC is also good if you don’t want lots of penetration, for example, when welding thin rusty areas of metal. This machine can handle up to 1/8″ stick electrodes.

This unit is relatively lightweight at under 200lbs and comes with low lift grab bars make it easier to move.  The 1-1/4″ diameter tube frame is also great for providing a bit of extra protection for the machine. Overall, this machine is -perfect for anyone looking for a high-quality, portable AC stick welder/generator.

Specifications

Brand Lincoln Electric
Model Bulldog 5500 140
Process Type AC Stick
Amperage Range 70-140A
Duty Cycle 30% @ 125A
Engine Kohler CH395
Continuous Power 4000W
Peak Power 5500W
Engine RPM 3600
Fuel Gasoline
Tank Size 1.9gal
Weight 198lb
Warranty 3 Year
Full specs Specifications

Pros

  • Lincoln quality machine
  • Suitable for welding magnetized steel
  • Low grab lift bars
  • Solid metal frame
  • Lightweight

Cons

  • AC only
  • Lower penetration
  • Small tank size
  • Running gear not included

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