I'm looking for a TIG welder that will work for doing 16 gauge stainless headers to 1/4" thick flanges. It also needs to be able to handle 1/4" thick aluminum. I'd like a machine that is 50 and 60 hz capable.
Any suggestions? What do you think about the Miller Maztar 200?

 

You probably should have put this in the fab section.
But I use a Miller synchrowave. To weld 1/4 aluminum you are going to need at least 250 amps or you will have to preheat the aluminum

 

I'm happy with my Lincoln Square Wave 175. Seriously, any TIG will work out fine. Lincoln, Miller, Hobart (i.e. Miller), etc... Even the home built Briggs & Stratton w/ alternator TIG. If you don't mind spending $2k+, the new solid state boxes are awesome. Very adjustable, they work on 110/220V, and only weigh about 35 lbs instead of 200 lbs. I have welded 1/4 aluminum w/ the 175, maxed out. If your butt welding it, you'll need to do several passes. Fillet welds, I would still bevel the edge. Stainless you need much less heat.

 

for anything except aluminum or any white metal i'd run tig off a stick machine and forget all the extra expense and parts of a dedicated tig outfit. however since you want to weld aluminum too i'd look at what miller has to sell and i'd look at 300-350 amp machines. i have a 250 amp and seldom weld aluminum but when i do it isn't near big enough