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Any recommendations for a good, inexpensive small welding unit just for ocassional use?

What kinda welder are you looking for,a stick welder,or a MIG?

It's really hard to beat a wire feed welder for all around easy use. You may already know this but, if you're going to be doing sheet metal you'll want a machine that you can hook up gas. Some really cheap machines are capable of flux core only. Good if you're welding outside where you don't have to worry about wind blowing your shielding gas away and if you're welding thicker gauge steel and not worried about the messy spatter of flux core.
A friend of mine has an Astro Pneumatic MIG and it beat the pants off a Miller I tried. 115V and 130 amps (doesn't get much higher than that on a 115 welder). This is a good price here and maybe free shipping? Astro MIG
I've used old Hobart TIG welders before and liked 'em. Don't know if their new stuff is as good. Here's a ready to weld flux core machine that has optional gas conversion kit. Looks like free shipping on this one and notice the $25 DISCOUNT which ends tomorrow. Hobart
And last but not least, the Lincoln Weld Pak 100HD (don't confuse this with Weld-Pak 100 that's flux core only) is a 115 welder that comes ready with flux core but, also has MIG conversion capability by buying separate kit. I've welded up to 3/16 on this machine with no problems. Lincoln
Check your local mom and pop welding stores. They may have a couple of these models that you may even be able to try out. Then ask them if they'll price match.
All this welding talk, now I've gotta go weld something. I'm gonna blame you Bob when wifey wants to know about the honey-do list!
-David

mugsy - thanks man, I'll take a look at these babies. I appreciate the recommendations.

I like the looks of the Astro Pneumatic MIG13. I'm gonna check the local shops before I order it online though. Maybe I'll get to test drive one!

P.S. - I see you're stationed in San Diego - Brought back some memories of TJ & Nasty City from when I was a young sailor stationed in SD back in the early 70s! WAY too many good times... probably the cause for the first ex-wife!

I recently purchased the Miller 175 wire feed welder. I went this direction at the advice of my father that is retired from the aviation welding profession after working for TWA/American Airlines in Kansas City for the past 35 years. He did a lot of research for me on the Hobart, Miller, Astro, Lincoln and a few other manufacturers I have not heard of. I run .030 wire and CO2/Argon mix. I have replaced floor pans, kick panels, rockers and some light structural components with this machine. I really like the performance of the machine and I am able to get gas, wire, tips, nozzles and any other parts from the local Praxair location. There are cheaper machines available, but it is hard to beat the performance of the Miller, Lincoln and Hobart for value, local servicing and available supplies.

Best of luck in your decision and purchase. It is nice to have the peace of mind knowing that you can weld up panels, steering columns, brackets or whatever else you need instead of depending on the local weld shop, especially on a Saturday evening when you are trying to finish up that Stovebolt project.

Miller uses a copper transformer,The others,Lincoln,etc.use alumunum.Explains the cost difference.

My first mig welder was a used Snap On [Century].
I could not get a good weld out of it , and was begining to question whether or not I was ever going to learn how to use a mig. I ended up taking a class at the local college and loved the Millers that they had. Finally bought a Miller 175 and now would not give it up , what a difference! At my work we have Hobarts [made by miller] in our maintenance dept. and they seem to perform just as well but I have only used them a few times. The right tool does make the difference.