I'd second the 4-1/2 or 6 inch grinder with a thin cutoff disk. A really good cutoff disk is only gonna cost $4 to $7 and will be fairly easy to make a straight cut on that thin, uneven surface.

It's been a while since I've ran stainless mig but the first thing that comes to my mind is wire feed speed, seems like a lot at that voltage for vertical up. I'd try backing it off a bit and make sure you're pausing at the toes. Just curious, what's your material thickness?

I think once you get use to using a passive lense your productivity will be about the same as with the auto-darkening. As MinnesotaDave stated a few of the tricks he uses, I do similar things, the more you use the passive you'll find tricks that work good for you. Keep a few different lense shades h...

I got a slide rule type of thing from Arc Zone with an order this past winter that is similar to what you're talking about. It list material types, thickness, recommended amperage settings, etc. They might be a good resource to check with.

I have the Grizzly G0561 bandsaw, when I bought it the cost was right around $800. It was an excellent purchase. The castings are good, coolant system works well, and most of all it makes clean/straight/true cuts. The only thing I don't like is what it takes to make 45 degree miter cuts, there are t...

I have a DeWalt magdrill and have been very happy with it. Bought it from the Mac Tools dealer that comes to the shop for just under $800. It has earned it's keep in the couple years I've had it.

This is a rack I made out of stuff I had laying around, main legs are 2.5"x 2.5" square tube .25 wall. The arms/shelves are 3" C-channel. Hope this gives you some ideas, sorry the picture isn't any better.

Very cool project.