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I appreciate your taking the time to educate me on this. It's not my area of expertise. Yes, I know the welder is a short. Is it really a significantly different load than the starter on a 5 ton truck?

I have an M1010 with the Plan B Mod, with a 100A 24V alternator and a 160A 12V alternator, both Leece Neville. I'm not sure how they rate for reliability, but I've been lucky so far. I was thinking that the running engine minimized stress on all parts when jumping, welding, etc. The batteries...

I've not tried welding on the truck. I've removed the parts I needed to weld. If I did have to weld on the truck, I'd completely disconnect the batteries from all but the slave port. You definitely don't want welding current passing through your ground path. Whatever in that path doesn't get...

sorry. duplicate eliminated.

Both. I wouldn't do much without the alternators running.

Same reason you have a dial to adjust amperage on other welders. These batteries are rated for 1000 amps at 24V. That's a *lot* of juice! Of course, the wire in the welder limits the actual current flow to far less, but it's still too hot for many tasks. Keep in mind that novice welders like...

I keep a 3' length of stainless steel resistor for that purpose, it was part of an industrial heating element. I wired a slave cable plug for power. Works great!