That's a good bit of overkill on the gas engine's HP. For my 90A alternator I could spin it at full power with a 9HP Honda engine. The electric motor I'm using now is only 1.5HP and just barely slows down when striking an arc at full power. The main reason I switched over to using my air compressor motor instead of the gas engine is that it is much much quieter and I didn't need the portability, I only built my setup so I could learn to TIG weld before I dropped the money on a real welder. As far as building this thing though, you guys are making it WAY more complicated than it really is. I'm pretty sure this guy isn't mounting this to a car or truck, he's planning on running it with a dedicated gas engine so none of that switching circuitry is needed. I draw up a diagram in paint to show how to wire the thing. It really is as simple as I'm saying it is.
Brad George
George's Welding & Repair
Amateur at TIG, MIG, and General Fabrication.
Current Equipment
AIRCO Heliwelder IV 300Amp Model - Total Awesomeness!
Hobart Handler 120v MIG