actually (not disagreeing with what you are saying) the Lincoln 135 is rated for 5/16 with .035 flux core... so technically, 1/4 is plenty doable...
True....BUT..as a i stated before..why put a machine at it's limit when using it for things that are safety related where it MIGHT work fine?..or worse yet..give a false sense of confidence that it is safe?.
This subject has been tackled,argued,one way to the other back and forth all over the net and in person,,but it always boils down to the people who DO weld and fabricate for a living are the ones who disagree TOTALY that these 110v machines are sufficeint for anything past 1/4",no matter what the "advertised" potential for a 110v machine for the sales pitch...for a GOOD reason.
When you use .035 wire on a 110v machine,you will have to turn it up as high it will go to get good penetration AND be able to keep up with the heat needed for .035..as i've heard from some who just don't know..turning the wire speed down to "seemingly" make it a hotter pass is a mis-conception..turning the wire speed down only causes the wire to burn off further away from the weldment,causing the heat to be FURTHER way from where it NEEDS to be,IN THE WELDMENT...not above it.
I don't care what anyone suggests about the wire speed,there is only one RIGHT wire speed according the heat being used in the machine and size wire being used..
...too much speed causes the wire to burn IN the puddle,this causes several problems..a fill that LOOKS like its filled,but yet only burned in a little but the extra wire that is being burned is just laying on top of the actual weld where it was actualy "burned in".
Not enough wire speed will cause the wire to burn BEFORE it gets to the needed area needing the penetration,it will cause the puddle to lay high on the weldment,causing very little penetration where needed..it's just laying there..it looks "pretty" because it MAY lay flatter,but it's conceiving to the untrained eye because underneath it did not penetrate INTO the base metal.
All your heat is generated at the VERY tip of the wire/rod being used..so that spot right there HAS to be where the penetration is needed..and with a 110v machine it is MUCH more critical to get that just right,for the fact it just plain old does not generate much heat for thicker material...a 220v is more forgiving,especialy for the amatuer because it generates ALOT more heat to get a BIGGER area of heat and "burn in" and fill,so that insures someone who doesn;t do it every day as a career has that much more insurance that they will get a much better weldment that will hold up...
Bottom line AGAIN..i just plain and simple will NEVER say"sure it's ok,because you have nothing else to use,go ahead and use it,it'll be just fine buddy!"
..i'm a bottom line type of person and NEVER sugar coat,whether it's my family,,freinds or even my worst enemy..i am un-biased when it comes to people and opinions..i never take a side just because he/she is my freind,if i did,,i would be a liar just to take a side to be a freind,and that's not gonna happen with me...