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In many cases, you also want to weld off the power grid with your portable welder. For this type of work, experts recommend a good engine driven welder-generator.
As you might know, there are so many welder generators for sale. But which one is good for you?
To help you out, I’ve collected a lot of information about welder generators in this 2000+ word article right here.
And to be honest, when you buy a product over one of my links, I will get some additional earnings myself. Of course, at no extra cost for you!
So, to make the decision process easier for you, I summarize relevant facts of the most popular welder generators below.
Table of Contents
You can use the links below to quickly navigate through the article or just continue reading.
Lincoln Bulldog 5500 (K2708-2)
With its tube frame, it is very rugged and provides up to 140 amps AC output. This portable Lincoln welder is suited for AC welding up to 1/8 inch with a stick electrode.
The 5500 in its name stands for its peak power which is 5500 W. The continuous output power is 4000 Watts AC power.
The Lincoln Bulldog 5500 welder generator is probably the one generator on the market with a very attractive price for low-budget welders and home users.
Lincoln Bulldog 5500 Portable Engine Driven Welder – Tube Frame Design
Bulldog 5500 – specification
- Engine Type: Kohler CH395 8,9 HP gasoline engine with cast iron cylinder. 1 cylinder design.Input Voltage: 110 V
- Power: 4000 W continuous AC power and 5,500 Watts peak. with two 120 V / 33.3 A and one 240 V / 16.7 A receptacles.
- Weight: 198 lbs
- Welding Capacity: Stick welding @ 70-140 A, up to 1/8 in. stick electrode
- Fuel Capacity: 1.9 Gals
- Fuel Consumption (Full Load): 0.74 Gals./Hr
Lincoln Electric Bulldog 5500 demo video
Bulldog 5500 – Pros and cons list
- Good price/performance ratio
- Rugged tube frame design
- Low weight compared to other machines
- Limited in power
- Only capable of stick welding
- Low fuel capacity
Engine Driven Welder, Bulldog 5500
- Series- Bulldog 5500
- Start type- Recoil
- Amperage range: 70-140
- Peak auxiliary power- 5500W
- Continuous auxiliary power- 4000W
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Hobart Champion 145
The Hobart Champion 145 is a cost-effective 4,5 kW powered engine driven welder generator.
Hobart Champion 145 – specification
- Engine Type: Briggs&Stratton Intek, 10 HP gasoline engine
- Power: 4000 W continuous AC power and 4,500 Watts peak. Four 120 V / 20 A receptacle and one 240 V 6-50R receptacles.
- Weight: 222 lbs (with running gear)
- Welding Capacity: Stick welding @40-145 A, up to 5/32 in. stick electrode
- Fuel Capacity: 6.25 Gals
- Fuel Consumption (Full Load): ~ 0.76 Gals./H
Hobart Champion 145 – demo video
Hobart Champion 145 – Pros and cons list
- Good price/performance ratio
- Rugged tube frame design
- Low weight compared to other machines
- Limited in power
- Only capable of stick welding
- Hobart Champion 145 Welder/Generator - 10 HP, 4,500 Watts, Model# 500563
- Occupational Health & Safety
- Country of Manifacturer: United States
- Manufacturer: Hobart
*Affiliate Disclosure / More Information
Lincoln Ranger 250 GXT
The Lincoln ranger 250 GXT comes with electrical ignition and lots of power. Thanks to the high power this device delivers, you can even use it for plasma cutting.
Moreover, it is remote ready which means you can operate this welder generator with remote control. The machine comes with a fuel meter and engine hour meter.
Ranger 250 GXT
Lincoln Ranger 250 GXT – specification
- Engine Type: Kohler Command, 24 HP gasoline engine with two cast iron cylinders.
- Power: 10,000 W continuous AC power and 11,000 Watts peak. Two 120 V / 20 A receptacles and one 240 V 42 A receptacles.
- Weight: 602 lbs
- Welding Capacity: Versatile AC/DC welding output enables stick, TIG, MIG & flux cored welding up to 250 A
- Fuel Capacity: 12 Gals
- Fuel Consumption (Full Load): ~ 1.7 Gals./H
Lincoln Ranger 250 GXT – demo video
Lincoln Ranger 250 GXT – Pros and cons list
- Remote control ready
- High continuous power
- Low fuel consumption
- Multi-process machine
- Price
- Weight – with 602 lbs this machine is quite heavy
Engine Driven Welder, Ranger
- Totally enclosed case, which ensures engine is fully protected
- Use as an AC generator for high-capacity needs such as backup generator
- Painted roof, case sides and engine doors
- Series: Ranger
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Miller Blue Star 185
A popular miller welder generator for sale is the Miller Blue Star 185. Miller Blue Star 185 is a compact device that comes with electrical ignition. Overall, the Miller welding generator provides 6,200 W of continuous AC power.
Miller Blue Star 185 – specification
- Engine Type: Kohler CH440 13.4 HP gasoline engine with two cast iron cylinders
- Power: 6,200 W continuous AC power and 6,500 Watts peak. Two 120 V / 20 A receptacles and one 240 V 26 A receptacles.
- Weight: 296 lbs
- Welding Capacity: stick/TIG welding 185 A @ 25 V, 20% or 150 A @ 25V, 100%
- Fuel Capacity: 6.25 Gals
- Fuel Consumption (Full Load): ~ 1.0 Gals./H
Miller Blue Star 185 – Pros and cons list
- Electric start & auto idle function
- Small in size for its power
- Low weight for its power
- Fuel capacity in mid range
- Power in mid range
Engine Driven Welder, Gas, 13 HP
- Price For: Each Start Type: Electric Item: Engine Driven Welder Includes: GCFI Recepticles Rated Output CC/DC: 185A @ 25V, 20% Phase: 1 Continuous Auxiliary Power: 62, 000W HP: 13 Peak Auxiliary Power: 65, 000W Height: 24-51/64" Depth: 31-19/64" Rated Output CC/AC: 185A 25V @ 20% Duty Cycle Series: Blue Star 185 Fuel Type: Gas Engine Brand: Kohler
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Hobart Champion Elite
The Hobart Champion Elite is a gasoline powered welder generator with high fuel capacity and lots of receptacles.
Designed with 9.500 W continuous AC power it is a heavy duty machine with enormous power capacity. Thus, it is suited not only for welding but also for any additional tools you need to get things done.
Hobart Champion Elite – specification
- Engine Type: Kohler 23 HP gasoline engine with 2 cylinders
- Power: 9,500 W continuous AC power and 11,000 Watts peak. Four 120 V / 20 A receptacles and one 240 V 50 A and one 120/240 V 50 A receptacle.
- Weight: 490 lbs
- Welding Capacity: stick/TIG welding 225 @ 25 V (100% duty)
- Fuel Capacity: 12 Gals
- Fuel Consumption (Full Load): ~ 1.0 Gals./H
Hobart Champion Elite video
Hobart Champion Elite – Pros and cons list
- High power output
- High fuels efficiency
- Weight
- Expensive
- Hobart Champion Elite Welder/Generator - 23 HP, 11,000 Watts, Model# 500562
- 225-amp Welder with 11,000-Watt Auxiliary Power 225 amps allows for ample welding capability. Weld up to 1/2" material and plug in your welding tools to get the job done with ease.
- Has a 12-gallon fuel tank and low oil pressure shutdown. Dependable engine conserves fuel and provides long operation before refueling.
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Miller Trailblazer 325 EFI (907754)
The Miller Trailblazer 325 with electronic fuel injection (EFI) is designed for professional welders. According to Miller, it delivers an unbeatable arc performance and provides the smoothest and most stable arc in the industry.
Thanks to Millers Auto-Speed technology, this engine will run quicker when you need more power and slow down when less power is required. Thus, the fuel efficiency is improved and the machine will adapt to any load automatically.
As a plus, this machine is a real multi-tool because it is capable of stick, TIG DC, MIG welding and even flux cored, plasma (PAC) and CAC-A cutting.
Miller Trailblazer 325 – specification
- Engine Type: Kohler ECH730 23 HP gasoline engine. (2 cylinder, 4 cycles, air-cooled)
- Power: 10500 W continuous AC power and 12000 Watts peak at 120 V. One 120/240 V 50 A receptacle when ordered with Excel power option
- Weight: 491 lbs
- Welding Capacity: Stick/TIG welding 325 A @ 28 V, 100% and MIG welding 325 A @ 28 V, 100% duty cycle
- Fuel Capacity: 12 Gals
- Fuel Consumption (Full Load – welding): ~ 1.9 Gals./H
Miller Trailblazer 325 video
Miller Trailblazer 325 – Pros and cons list
- Machine power adapts to load (Miller Auto-Speed Technology)
- Smooth arc performance
- Weight
- Price
Trailblazer 325 Engine-Driven Welder #907754
- Designed for the professional welder, our trailblazer welder/generators deliver unbeatable arc performance, the smoothest, most stable arc in the industry and an independent welder and generator powe
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Miller Bobcat 250
If you are looking for a welder generator that is diesel powered you might check out the Miller Bobcat 250.
The Bobcat 250 has a front panel which shows current fuel level. As a plus, the engine will stop before the system runs out of diesel. This makes restarts easier.
The special skewed-rotor design inside the generator provides smoother power compared to most competitors.
Miller Bobcat 250 – specification
- Engine Type: Kubota D722 19 HP diesel engine with three cylinders (liquid cooled).
- Power: 9500 W continuous AC power and 11000 Watts peak at 120 V. Two 120 V receptacles and one 120/240 50 A receptacle
- Weight: 638 lbs
- Welding Capacity: Stick/TIG welding 250 A @ 25 V, 100% and MIG welding 250 A @ 28 V, 100% duty cycle
- Fuel Capacity: 12 Gals
- Fuel Consumption (Full Load – welding): –
Miller Bobcat 250 demonstration video
Miller Bobcat 250 – Pros and cons list
- Rugged diesel powered engine
- Smooth power output
- Maintenance display provides information about fuel level, engine hours, oil change interval and more
- Very high weight
- Price
Miller Bobcat 250 Diesel Engine-Driven Welder / Generator 907565
- Engine Driven Welders
- Multiprocess And Engine Driven Welders And Accesso
- Welding
- WELDING & SOLDERING
*Affiliate Disclosure / More Information
What is the typical use case of an engine driven welder-generator?
So what exactly is a welder/generator and what do you use it for?
The engine driven welder generator is a piece of equipment that is fuel powered and provides you with electricity when you have no other electric power source available. You can use it for welding and even more.
Lincoln Bulldog 5500 Portable Engine Driven Welder – Tube Frame Design
For example, farmers use this type of mobile welding machine for maintenance repair work. Think of fence repair, constructing barns, repairing trailers and farm equipment. Also, think about construction work in the oil and gas industry.
You can also use the welder generator as a portable standalone generator which provides electrical power to any electrical device.
Moreover, you can run other equipment – like lights or grinders – while you are welding.
Some typical applications for welder generators:
- Maintenance work
- Construction sites
- Farm equipment repair
- Car frame construction work
- Trailer repair
- Pipeline construction
- Equipment rental
- Home use
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Buying guide – how to choose the best engine-driven welder-generator?
How much generator output do you need? 1kW or 20 kW phase?
Depending on the number of tools or devices you want to run simultaneously you need more or less power. Also consider your welding job and the thickness of steel you need to weld.
In general, the more power you need, the more expensive your welder generator will be.
Electric start
For the reliable and more comfortable start consider electric start feature. Pull-start can be difficult when the device is mounted on the back of your truck.
Gasoline, Diesel or propane gas – what fuel type is best?
Engine driven welder generators can be powered by gas, diesel or propane fuel engine. Choosing the right fuel type can be critical. Let’s take a closer look at the properties of those fuel types.
Gasoline
Easy to use but some job sites don’t permit gasoline on the job sites as gasoline is a little bit more dangerous to use than diesel.
Furthermore, it requires more maintenance than Diesel because of the electrical ignition. Regular tuning and replacement of spark plugs will be required.
Diesel
A Diesel engine is more expensive, but its efficiency is very good and the fuel consumption of diesel is lower than gasoline.
Diesel engines are more rugged and require less maintenance than the other options. Usually, the only things you need to do is oil and filter changes.
Diesel, in general, is safer to store than gasoline or LPG.
At temperatures below freezing point, diesel engine could be harder to start and might need some additional starting help.
Propane gas (LPG)
Propane gas, sometimes also called liquid petroleum gas (LPG).
Compared to gasoline and diesel, propane will not degrade when stored for longer time. So this could be a good option if you don’t use the generator for longer times.
On the downside, propane is less efficient than diesel or gasoline, and an additional gas tank is required.
Type of processes you want to run
A very important question is, what processes do you plan to run most of the time?
Think about stick/TIG/MIG wire feed welding.
There are many welder generators on the market that are multi-process machines.
Do you plan to stick/TIG/MIG and/or wire feed weld with your welder generator?
Do you plan to run a plasma cutter?
Besides that, what additional equipment do you want to run with the generator? Do you need a compressor, grinder, working lights or other hand tools?
Does your mate grind your weld work while you are doing another welding job?
To sum it up, please don’t forget to calculate your required power consumption if you use multiple tools at the same time.
Fuel tank size
Welding time depends on the one hand on the fuel type and on the other hand on the fuel tank size.
Bigger tanks, in general, give longer welding times.
Tank sizes vary from 5 gallons to over 25 gallons so you better know how big your tank should be.
Portability and weight
There are welder generators which are portable and lightweight.
However, high power devices are heavy and big. To be mobile, you need to mount those on your truck or a trailer.
Consider adding cable racks and tools on your trailer.
If you plan it to put it on your truck, how much weight can your vehicle handle?
If you plan to mount it on your truck, I saw there are 3D CAD files devices available (at least for the Lincoln Electric devices). With this 3D data, it should be easy to plan your mounts.
Make sure to get a quiet and rugged machine, if desired.
Frame design and size
There are two different frame designs on the market. The Tube frame design and the enclosed case design.
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- Lincoln Bulldog 5500 Portable Engine Driven Welder – Tube Frame Design
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- Lincoln SAE-300 Engine Driven Welder for Construction and Pipeline industries – Enclosed Case Design
Tube frame welders are usually more compact and lighter than devices with an enclosed case.
Moreover, tube frame welder generators can be lifted more easily by hand or with a crane from your pick-up truck.
Additionally, for highway trailers, there are protective frames available. Put those on your welder generator so that it doesn’t get damaged.
Also consider, if you plan to put the generator on the back of your truck, how much space on your truck can you give away for the welder generator?
How to save money?
Buy a used welder generator or consider sharing it. If you don’t need it often, you can also check out rentals near your place.
Auto idle feature idles your machine automatically down when you don’t use it. This helps to run quieter and use less fuel when no power is required.
back to menu ↑Accessories for your welder generator
The right accessories can help you to improve your welding job. A remote control lets you change amperage if you are 200 ft. away from the machine. You should prefer wireless remote controls because these are more versatile than wired remote controls.
Think about additional cylinder tank for gas powered welder generators. If you want to MIG weld, you need a portable wire feeder.
Another excellent piece of equipment could be a protective cover to protect your generator. And make sure to get a set of cables that fit your generator.
Safety equipment
Make sure to get proper safety equipment for welding like welding jacket, welding gloves and welding helmets.
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