Not everyone needs a 200-amp machine. If you are learning to weld, or you only fix gates, brackets, and workshop gear once in a while, a small 120V stick welder will cover most jobs you will ever face.
That is the niche the Forney Easy Weld 100 ST has owned for years.
The current version, the 100 ST-i (Forney item 297), is an 80-amp inverter that weighs 5.8 lb and runs on a standard household outlet.
In this Forney Easy Weld 100 ST review, we look at what the updated machine actually does: the real amperage range, the duty cycle, stick and lift TIG performance, and the fine print about power draw. It holds spot five in our best stick welder roundup, and the reasons cut both ways.
Short version: it is a better machine than the old 100 ST it replaces, as long as you respect its 80-amp ceiling.
Forney Easy Weld 100 ST Review: Package Content & Technical Specifications
Forney ships the 100 ST-i as a lean kit. There is no case and no extra torch in the box, just the working parts:
Lightweight 120V Stick and Lift TIG Inverter
- Forney Easy Weld 100 ST-i welder (item 297)
- 6 ft electrode holder and lead
- 6 ft ground clamp and lead
- 7 ft power cord, 120V plug
- 15-to-20 amp plug adapter
- Quick Start Guide (English, Spanish, French)
- Nylon carry strap
Technical Specifications
| Welding Process: | Stick (SMAW) / Lift TIG (DC) |
| Input Voltage: | 120V AC, 50-60 Hz, single phase |
| Input Current: | 15 amps |
| Stick Output: | 15-80 amps |
| TIG Output: | 15-85 amps |
| Duty Cycle: | 30% @ 80A stick / 30% @ 85A TIG |
| Material Thickness: | 24 ga – 1/4 in, single pass |
| Max Electrode Size: | up to 1/8 in |
| Open Circuit Voltage: | 75V |
| Weight: | 5.8 lb (2.6 kg) |
| Generator Use: | 4,000 W min, 5% THD max, no low-idle |
| Warranty: | 1 year |
Pros
- Weighs 5.8 lb; one-hand carry to the job
- Runs on any standard 120V household outlet
- Hot Start and Arc Force built into one knob
- Lift-start DC TIG for thin steel
- Works on clean generator power (4,000 W+)
Cons
- 80-amp ceiling limits rod size and thickness
- 30% duty cycle at full output
- TIG torch, argon, and regulator sold separately
- DC only, so no aluminum welding
- Analog dial, no digital display or memory
How the Forney Easy Weld 100 ST Welds
Forney Industries positions the 100 ST-i as compact welding equipment and a portable device for DIYers and hobbyist users. A Quick Start Guide is included, which helps new welders learn basic setup and maintenance. It is simple to operate for new welders, and beginners often find it easy to use and forgiving because the one-knob layout reduces variables. You set the amperage on the analog dial, and the built-in Hot Start and Arc Force do the rest, giving better control over the arc. Hot Start bumps the current at the strike so the arc lights instead of the rod freezing to the plate, and Arc Force keeps the arc steady as the electrode gets short for a nice bead.
The numbers that matter: 15-80 amps on stick, 15-85 amps on lift TIG, a 30% duty cycle at full output, and enough power for single passes on steel from 24 gauge up to 1/4 inch. Forney rates electrodes up to 1/8 inch, which sets the practical ceiling for rod size, so electrode choice should match the material you plan to weld. The 100 ST-i measures 10 x 4.3 x 7.4 inches and weighs 5.8 lb.
Stick Welding on the 100 ST-i
E6013 rods in 3/32 inch are the sweet spot. The simple one-knob setup gives a beginner or hobbyist more control over travel speed, rod angle, and other variables, so this stick machine burns them clean on sheet metal, thin angle iron, and mild steel between 50 and 70 amps.
Hot Start also helps with E6011, which matters when you are still learning to strike an arc without sticking rods. If rod basics are new to you, Everlast has a solid primer on what you can do with E6013, and I’d recommend the Forney E6013 electrode as an easy starting point.
Thicker stock is where you work within the limits. With 120-volt input it runs stick in the 15A to 80A range and lift-start TIG in the 15A to 85A range; 1/8 inch 7018 runs near the top of the dial, and above 1/4 inch the honest answer is multiple passes. The duty cycle is about 30% at 80A, which means roughly three minutes of arc-on time out of every ten; on thin repair work you will never hit it. Electrode choice and base material affect results, and the simple, task-specific setup makes it easier to learn and lay a clean bead.
Lift TIG Welding Without the Price Tag
The lift TIG function is the surprise of this price class. For mild steel work, I’d still recommend E6013 as the easiest rod choice for this stick machine. Instead of scratch-starting and grinding tungsten afterwards, you touch the tungsten to the metal, lift, and the arc starts clean.
On DC you can lay tidy beads on thin steel from 24 gauge up, which is useful for body panels and tool repairs.
Hobbyist users can learn quickly on common mild steel because it also supports stick welding with E6013 electrodes.
Budget for accessories, because none of the TIG gear ships with the welder. This is not a dedicated TIG welder: for TIG welding you need gas for shielding, while stick mode does not, and the practical limit is mild steel up to 1/4 inch thick. You need a DC TIG torch with a 25-series Dinse plug, an argon bottle, and a regulator. Forney sells the machine through its own site and Amazon, and the torch kit is a separate buy either way.
Power Draw and Circuit Breakers
The 100 ST-i draws 15 amps from a 120V outlet, which is exactly what a household circuit supplies. It runs best on a 20-amp circuit, and Forney includes a 15-to-20 amp plug adapter so the plug fits both outlet types. If you share a 15-amp breaker with lights or a grinder, expect it to trip when you push the dial toward 80 amps.
Extension cords are where beginners lose arcs. A long 16-gauge cord drops enough voltage to starve the machine, so use a short 12-gauge cord or plug in directly. Generator power works too: Forney specifies a 4,000-watt continuous unit without a low-idle mode and with total harmonic distortion under 5%.
Frequently Asked Questions [F.A.Q]
Will the Forney Easy Weld 100 ST work on low input voltage?
Yes, within reason. The welder is built for 120V household current and has internal protection that shuts it down when voltage drops too far, which usually happens on a long or thin extension cord. If it keeps cutting out mid-bead, shorten the cord or move to a dedicated outlet. The shutdown protects the inverter; it is not a fault.
Do you stick weld left to right or right to left?
Either direction produces a sound weld with general-purpose rods like E6013. Most right-handed welders drag left to right so they can watch the puddle. Direction matters far less than steady travel speed and a consistent rod angle, which is half of learning how to stick weld anyway.
Can you hold the electrode while stick welding?
No. The electrode holder is insulated so your hand stays safe, and you should never touch the rod or the workpiece with bare skin while the machine is on. Sweat and damp gloves raise the shock risk, so keep gloves dry and replace a holder once its insulation cracks.
Can the Forney Easy Weld 100 ST weld aluminum?
No. The output is DC only, and aluminum TIG requires AC. There is no MIG function either, so a spool gun is not an option. For aluminum you need a small AC/DC TIG machine or a MIG welder with a spool gun; the 100 ST-i is a steel and stainless machine.
Conclusion
For thick structural steel welded all day, look elsewhere. For everyone else, the Forney Easy Weld 100 ST-i at around $175 is hard to beat: 80 real amps on stick, usable lift TIG, Hot Start that forgives beginners, and a 5.8 lb body you can carry to the work instead of dragging the work to the bench. That combination is exactly why it keeps its place in our stick welder lineup.
