Pic #1:
.065 wall cap welded on to 2.5" diameter .065 tubing. The key there is to have the cap set back from the tip of the tubing. If it was flush on the outside, it would not look as good. #12 cup, 3/16" 2% tungsten, no pulse, just foot pedal and no filler rod. Amperage is at about 40A, and moving rather quick.
Pic #2:
Same thing as on the cap. The -6an fitting is mild steel, .045 filler rod, 55A foot pedal, no pulse.
Pic#7:
This was a but weld. .065" 3" diameter 304SS tubing. Sames torch setup as before, 60-65A, 1/16" filler rod, also foot pedal only and moving at a decent pace.