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A 200- or 250-amp machine is usually big enough for most stick welding applications, Snyder indicates. "A 200-amp machine is probably a little bit on the small end for wire welding," he adds. "A 300-amp machine is probably pretty good for handling a lot of different diameter wire."

Ultimately, the determining factor between wire and stick is the size of the typical repairs. "If half of your jobs are bigger ones, then you really should look at flux-cored," says Leisner. "But if most of them are smaller, stick is probably the easier way to go."

Consider weight
Contractors are moving toward smaller and lighter service trucks. "The costs of service trucks has really skyrocketed since 2007, when the new emissions went into effect," says Leisner. "So smaller and lighter really saves them a lot of money now vs. what it used to."

But smaller trucks also mean less available payload capacity. This has driven the popularity of gasoline-powered welder generators. "More of them actually use gas than diesel because of the size, cost and weight," says Leisner. "Diesel units usually have a longer engine life than their gas counterparts and can use less fuel, while gas engine drives are typically less expensive and are smaller and lighter. We do make some light diesels, but the gas machines are still 200 lbs. lighter."

Diesel engines do offer greater longevity, but this is not often an important consideration in repair work. "Because the core job is not welding, [the technicians] will not wear out an engine anyway," Leisner points out.