Shawn: I'll let some other members address your other questions, but I would like to suggest you do not use the 110 welder to do any serious suspension or frame welding. You just will not get the penetration you need to make these as strong as you need them to be.

Spot weld them and take them to a pro welder, or someone who has and knows how to use heavier duty stuff, and have it done there. I do exactly that myself, because I know my limitations, and I don't want to hurt me or someone else if a weld fails.

I've always read your posts, and you impress me as being really smart. Don't take a chance with something so critical.

Don