mig welder wire

use .23 wire and get a good quality wire like lincoln cause it will weld better and you can actually run a bead with that .23 wire if you tune your welder right but don't do too long of a bead cause you will cause it to warp to much. i weld for a living and i use the 23 for the sheet metal and the 35 wire for thick stuff.

.030 will be fine.

.23 is almost 1/4"!!! .023 is what you need for the thin stuff, that way you can turn the machine way down and not have a cold weld.......

run whatever brand wire you want, except campbell hausfeld.. you wont notice much of a difference at real low amps.....

cris- My supplier has me trying a different wire (I can't remember what brand right now) and it seems to be okay. My machine has a few miles on it and it's starting to show, so it's hard to tell if it's the wire that welds odd or the machine...