The stud welding process is used to join a metal stud to a metal workpiece by heating both parts with an arc.
Even though this process was first developed to increase shipbuilding and submarine production, it found its way into many different industries today.
Due to its high popularity in the automotive industry, stud welding machines became more popular and affordable. As a result, there are various types of stud welders. That’s why in this article, we answer the question of what the best stud welder is.
Best Stud Welder Comparison Table
| Welder Image | Name | Input Power | Rated Power | Country of Origin | Weight | Warranty | Check Price |
|---|---|---|---|---|---|---|---|
 | Motor Guard Super Pro Plus Kit | 110V | 2000 amps | USA | 26.6 lbs | 5 years | Check Current Price Eastwood |
 | StudPro 3125Xi Capacitor Discharge Stud Welder | 110/220V | 2280 watts per second | USA | 50 lbs | 1 year | Check Current Price Amazon |
 | Motor Guard Magna Deluxe Repair Kit | 110V | 1500 amps | USA | 26 lbs | 5 years | Check Current Price Northern Tool |
 | BELEY 110V Car Body Stud Welder | 110V | 3000 watts | China | 46.3 lbs | 1 year | Check Current Price Amazon |
| H & S Autoshot 4550 Starter Plus Stud Welder Kit | 110V | 1500 amps | Canada | 17 lbs | 3 years | Check Current Price Amazon |
Best Stud Welders Reviewed
Stud welders we are reviewing today come in different shapes and types. Some seem like traditional welding machines, while others are handheld and come into a common stud welder kit. So before you choose your stud welding machine, you must set your goals straight.
Fortunately, we saved you hours of grunt work and compiled a detailed list of the best stud welders you can find on the market today.
1. Motor Guard Super Pro Plus Stud Welder – Best Stud Welder For Autobody
The Motor Guard is one of the big names in the stud welding market, as they make quite a reliable and lightweight portable stud welders. Super Pro Plus is, in our opinion, an all-around best stud welder for autobody shops, as it offers everything you need to repair dents with ease.
Super Pro Plus, stud welder kit, includes a sturdy and reliable 2000 amp stud gun that operates at 110V. Somewhat higher weight is a result of heavy-duty construction.
However, I liked the fact stud welding kit includes 500 draw pins (250 of 2.0mm for thin metal and 250 of 2.5 mm for heavier-gauge rocker panels), 150 trim rivets, and 1/2-lb. of Magna Wire for welding along creases.
With Magna T-Puller and twist-on/off slide hammer, the value you get for the money spent makes Motor Guard Super Pro Plus an ultimate dent-removing tool. However, it is somewhat pricier than other stud welders that look like stud guns.
I liked how this stud welder is easy to use. The stud welder dent puller makes pulling dents from one side possible without drilling holes. Once you place the studs, twist on the slide hammer and pull out the dent until flush. On larger and deep dents, you should use multiple pins and gradually work each pin until the surface is level.
Since it might be necessary to some, we should note this machine is built in the US. In addition, you get an excellent manufacturer’s warranty that lasts five years.
Pros & Cons Summarized
Pros
- Suitable for thicker car panels and heavy-duty welding tasks
- One of the best stud welders for autobody shop
- Reliable and sturdy
- High-quality slide hammer and dent puller
- High package value
- 5-year warranty
- Comes in a sturdy case
Cons
- A bit heavy
- Expensive
Features
- Input voltage: 120 VAC 1 PH 50/60 Hz; 15 A
- Rated Power: 2250 watts
- 9-foot heavy gauge oil-resistant power cord
- 250 – 2.0mm pins, 250 – 2.5mm pins
- 1/2lb. – 16 ga. Magna-Wire Trim Rivets
- Low-Heat technology
- Weight: 26.6 pounds
- Made in the US
- 5-year warranty
2. StudPro 3125Xi Capacitor Discharge Stud Welder – Best Industrial-grade Stud Welder
If you do stud welding regularly in your fabrication or autobody shop, you should look for an industrial-grade stud welder. StudPro 3215XI is an excellent choice for everyone that expects a workhorse capacitor discharge stud welder. This is a well-built and reliable machine, but you will have to spend quite a few bucks to buy it.
StudPro 3125Xi utilizes a universal power supply input with a plug-and-play approach. As a result, you can use both 110V/220V to run it.
In addition, compared to the MG stud welder kit we reviewed, StudPro includes an intuitive touchscreen interface that you can use to select and save commonly used parameters.
As a result, you can use studs 14 ga to 5/16″. Furthermore, with weld energy of 2280 watts per second, you can achieve an efficiency of up to 14 studs per minute. Therefore, StudPro 3125Xi is an efficient and capable machine for various projects.
With a weight of 20.8 lbs, the StudPro stud welder is a compact but durable machine. Internal components are of rigid construction, and the outer texture increases durability and improves appearance. In addition, 3125Xi is made in a US machine that offers built-in overload protection and thermal protection, so with a 1-year warranty, your high investment is well protected.
I like the stud gun that seems sturdy, but comfortable and easy to use. There is a built-in tension spring that allows you to select the proper pressure for every welding application. In addition, gun can be configured to suit different studs and collets, and the #6,#8,#10,1/4″ and 5/16″ collets and mild steel CD weld studs are included.
Pros & Cons Summarized
Pros
- An industrial grade stud welder
- Plug and play power source
- Can achieve up to 14 studs a minute
- Suitable for various thickness
- Built-in overload protection and thermal protection
- Gun can be configured to suit different studs and collets
Cons
- Expensive
- The warranty is only one year long
Features
- Input voltage: 110 VAC @ 50/60 HZ 15 AMP; 220 VAC @ 50/60 HZ7.5 AMP
- Welding range: 14 ga up to 5/16″
- Duty cycle: 14 studs per minute
- Weld Energy: 2280 watts per second
- Great for: Mild Steel, Stainless Steel, and Aluminum
- 250 studs included
- Weight: 50 lbs
- Made in the US
- Warranty: 1 year
3. Motor Guard Magna Stud Welder Deluxe Repair Kit – Great Value Stud Welder For Autobody
We put MG Magna stud welder on our list as a cheaper alternative to the Super Pro Plus kit we mentioned at the start of the text.
This stud welder combines all the accessories and features, such as the Magna pin system, into a somewhat lower-rated and priced welding machine.
Motor Guard Magna stud welder is rated at 1500 amps, so it is more suitable for thinner metal. This model is rated and advertised as an intermediate stud welder, as it ranks between Super Pro Plus and Entry Plus Kit.
That also reflects the price, which won’t break your bank.
For the money spent, you get a heavy-duty slide hammer, 3 electrodes, 250 draw pins size 2.0mm for thin, 2.5mm for thicker materials, and 150 rivets. In addition, the sturdy case that this welder comes in includes Magna Clamp with a tightening wing nut to make jobs go faster and the Magna T-puller for minor damage repair and for reducing overpull when working on lighter weight.
Appearance-wise, some welders liked this Deluxe Repair Kit more than the Super Pro Plus stud welder, which is pink-purplish. I know color doesn’t affect the overall performance, but some welders have personal preferences. Regarding the build quality, this Magna stud welder is a well-constructed and sturdily made US machine. A 5-year manufacturer warranty supports these claims.
Talking about capability, many satisfied autobody shop owners say Magna Stud Welder outperformed their expensive machines. Stud welder dent puller and slide hammer are significantly higher quality compared to low-end ones. So overall, Magna Deluxe Kit is a great value purchase.
Pros & Cons Summarized
Pros
- Great value stud welder kit
- Suitable for light to medium duty projects
- Excellent accessories
- Durable and sturdy build
- Magna clamp with durable ground cable
- The US-made machine
- The warranty lasts 5 years
Cons
- Lacks some consumables compared to the Super Pro kit
- Not for heavy-duty jobs
Features
- Input voltage: 120 VAC 1 PH 50/60 Hz; 15 A
- Rated Power: 1500 watts
- Electrodes for Pins, Rivets & Shrinking
- 250 – 2.0mm pins,
- 250 – 2.5mm pins
- Low-Heat technology
- Exclusive Magna Pin System
- Made in the US
- 5-year warranty
4. BELEY 110V Car Body Stud Welder Dent Repair Kit – Best All-in-One Stud Welder Kit
If you are looking for an all-around machine designed to repair the dents for the auto body, but it is also suitable for sheet metal fire, meson, straight pull, spot welding, flattening, and wave line, this Baley stud welder is a go-to choice.
This machine has seven welding modes and ten power levels. Therefore, you can easily choose the correct welding mode and power according to the car’s body condition.
We included a 110V welder on our list because it is more versatile, as you can plug it into a regular household outlet. However, lower input voltage means lower output, so you should expect to stud weld car panels thicker than 0.024~0.047inches. In addition, some auto body shop owners report this 3 kW stud welder might struggle welding car lines as it is best for straight surfaces.
However, looking at the price tag of under $400 and the content package, you get an excellent value for the money spent. The stud welding kit includes accessories such as a dent pulling hook hammer, carbon rod connector, triangle chuck, manual sucker, carbon rods, triangle straight pull sheet, and a spanner for a wrench. But, keep in mind that you don’t get welding stud, meaning you will have to buy them separately.
Overall, this BELEY stud and spot welder is quite versatile and easy to use. You can simply select one of the seven different welding processes, such as spot welding, flattening, gasket welding, straight pull, stud, wave wire welding, carbon rod heating, etc.
Pros & Cons Summarized
Pros
- All-in-one stud welder
- Capable of stud welding, sheet metal fire, meson, straight pull, spot welding, flattening, and wave line
- Adjustable power and controls
- Great value for the price
- Various accessories are included in the package
- Versatile and easy to use
Cons
- Not suitable for car lines and thicker panels
- Studs are not included
- Some disliked ground clamp
Features
- Support voltage: 110V
- Input power: 3KW
- Max Input Current: 20A
- Working modes: 7
- Welding thickness of single side: 0.024~0.047 inches
- Weight: 46.3 pounds
- Made in China
- Warranty: 1 year
5. H & S Autoshot 4550 Starter Plus Stud Welder Kit – Starter Kit Edition Stud Welder
H & S Autoshot 4550 starter kit is an excellent entry-level stud welder that will help you get into an autobody business. To help you get started, this welder features an exclusive Stud Ease Technology, making it an easy process to use. Since it is a starter stud welder, the price tag is excellent, but many welders state it is a good alternative to buying a stud gun off of the tool trucks.
Since there were some complaints about the durability and old slide hammer, H & S Autoshot decided to upgrade the package.
Welders now get an upgraded 1016 T handle slide hammer that does the job well. With 17 lbs, this is one of the lightest stud welders on our list, but you might find it surprisingly heavy the first time you use it.
I’ve noticed that the package is somewhat more simple when compared to the MG Magna stud welder or BELEY machine. There are only a few accessories and a pack of 500 Flexpert welding studs of the same size. However, this H & S Autoshot 4550 is just a starting kit, so you shouldn’t expect more.
Overall, H & S Autoshot 4550 is one of the most popular stud welders on amazon due to its reasonable price and decent performance. Of course, you shouldn’t expect the power of the MG Super Pro Plus welder, but it will work great even with bigger dents as long as you clean the weld area to bare metal. In addition, you get a 3-year warranty, but satisfied owners say it worked well after more prolonged use.
Pros & Cons Summarized
Pros
- One of the most popular welders on the amazon
- A quite suitable and capable machine
- Upgraded slide hammer
- Lightest on the list
- Can deal with bigger dents
- Good warranty options
Cons
- Not for heavy-duty use
- Only one size studs included
Specifications
- Input voltage: 110 volt
- Rated Power: 1500-Amp Starter gun
- 500 pack of 2.2mm studs
- Stud Ease Technology
- 1016 T handle slide hammer
- Weight: 17 lbs.
- Made in Canada
- 3-year warranty
About Stud Welding and Stud Welders
Stud welding is the electric arc process that joins studs with parent metal using a welding arc and a pressing force. Edward “Ted” Nelson invented the stud welding process in 1939 at the Mare Island shipyard in Vallejo, California, as he wanted to speed up shipbuilding production.
A crucial difference between arc stud welding and other fastening processes is that the fastener is attached to the workpiece without marring the other side.
In addition, this is one of the quickest fastening processes, as studs are placed within a second. Depending on the principle of studs, there are two types of stud welding. Capacitor discharge studs are used for thinner materials, while drawn arc weld studs form strong, vibration-resistant welds.
Stud Welders And Important Factors
Before buying a stud welder, you should set your goals straight. If you are a full-time autobody shop owner, you should opt for an industrial-grade machine. Yes, that means you will have to spend some more bucks for the welders such as MG Super Pro Plus or StudPro 3125Xi, but the investment is well worth it.
These machines will help you weld even thicker body panels (up to 5/16″), and they are sturdy, reliable, and well built. The reliability will ensure there is no plastic deformation, burn-through, or low heat technology. In addition, these offer some high-quality accessories such as pulling rings and graphite rod holder and consumables such as studs and wavy wires, so you won’t have any issues when pulling out pins.
On the other hand, if you are tackling occasional light-duty to medium welding tasks, you can opt for cheaper stud welders such as H & S Autoshot 4550, or Magna Deluxe and Entry Level machines. Even though these don’t offer a complete kit, you will get various stud sizes and equipment for your everyday welding. The best part is they won’t break your bank, so even if you don’t use them regularly, you won’t regret spending the money.
Power And Capability
Even though stud welders are mostly aimed at the autobody industry and car body panels, there is a difference in power. As a result, 110V welding machines or capacitor discharge welders are more suitable for thin metal.
On the other hand, 220V welders usually offer more power, up to 3000 watts, so you can place a stud in nearly 0.6 seconds. This is important when efficiency and productivity are crucial. Some machines, such as StudPro 3125Xi, even offer a plug-and-play approach, meaning you can plug it into any outlet.
The duty cycle is important if you are looking for large-scale welding jobs, where every minute matters. That’s why a stud welder should have enough power with a good cooling system, and thermal protection, so you don’t damage the components.
Package And Accessories
Stud welder accessories can be an essential factor when buying a stud welder. High-quality stud guns should have an ergonomic design, be well constructed, and be easy to use. In addition, the slide hammer and dent puller should be capable of holding, not just damaging the pins.
Package content can be important, but it is not essential, as you can always buy some consumables. Nonetheless, starter kits won’t keep you going for too long, while a complete kit includes everything you need to stud weld longer periods.
