Chris (Soundguy) I'm always surprised how my perspective seems to run parallel to yours. I bought an old Wards AC 235 welder, and found that the manual for your modern hobart 235ac is a near-perfect match for explaining its design and how to use it properly. This rig seems to do anything I want.
My latest project was to repair the leg tabs for a cast-iron garden chair and matching table that my wife inherited. A shop told me $90/hour and probably two hours, for the project. He suggested I try some expensive nickel rod ($35/lb). With no cast iron experience at all, I did a fine job on it with my old AC welder , much better than I expected.
I remembered thingy's posts saying grind the welds until no lines remain. I welded, peened, then ground, several times to be sure I had continuous metal. I also was careful to avoid excess heat.
This picture shows the two repaired tabs plus one unbroken leg. The break on each tab was where the nut stressed it. I think the repaired legs are now as strong as the undamaged one.
There must be some application I will need a fancier welder for, but I haven't hit the limits of this one yet.