Hi Frank
I agree that the water cooled torches are typically more cumbersome because of the added size and coolant line but maybe Dan only wants to have one torch and he may be planning on welding aluminum or some other metal that sucks the current. In that case a water cooled torch is indispensible.
Of course I don`t know if you have welded any heavy aluminum but incase you haven`t, it`s not uncommon to need all of those 250 amps and then some, the torch will become very hot, not to mention the base metal being welded will require substantial preheat so why not remove any heat you can.
The add on hi freq units like you have are a very good choice for less demanding(current draw) welding, and if Dan is only interested in welding things like mufflers then you are right. The only shortcoming that I can imagine is you only have scratch start with these, or am I mistaken? I like having a foot pedal for amperage control but I also know that most guys doing small bore pipe in the field are using scratch start.
As far as freezing goes, I use propylene glycol antifreeze which is non-toxic in my water cooler. Although it`s expensive, two gallons is all I need.
As far as what machine to get, I absolutely love my Lincoln Square Wave Tig machine and a few Millers that I have tried out were just as nice. I would only buy an older Hobart because the new ones are reputed to be lower grade now that Miller owns them. Of course there are many other good brands of welders out there. You can sometimes find the older machines in good shape for a very reasonable price. Mine is 300 amps @ 100% duty cycle and will crank out 400 amps at 80%. Having all of the control that this machine offers is nice at times. The only downfalls are that the machine is big, requires an 80 amp circuit for charging the capacitors if running on 240v single phase and the cost is a little steep if you are buying new and you aren`t using it everyday. Other than that it`s the sweetest welder I have ever used.
Dan
Sorry for dragging your post somewhat off topic. Just wanted to offer my vote for another alternative. I may be able to find you a good used welder. I`m assuming single phase power?
Russ