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Sounds like your using a blade with too high of a teeth per inch count. Chips are likely not getting pulled out of the cut. No such thing as a one size does all bandsaw blade

Could be an aluminum alloy that isn't weldable.

Center punch and screw machine length ( stubby length) drills. Cutting oil and drill it in one shot, no pilot needed

5/16" floor screws? I use a 17/64" bit for those. Problem is that rusty scale is ruining the bit before you start. Needle scale or grind the scale off where you want the hole. I use either Viking or Norseman black and gold bits with lots of pressure and usually use the CRC cutting oil.

Probably get yourself a pipe stand. May have to modify the vee head to work

Primeweld. 285 is dual voltage around a grand. Otherwise the mig 180 is dual voltage around 600_

I prefer screw machine length ( stubby) bits for situations where a deep hole isnt necessary.

Yes

Vevor offers a set of bearing press plates in increments. It's in metric o.d. but goes pretty large in size. Last I checked the set with a couple arbors was around 70$

Keep in mind most of not all dual shield only comes in a 12" spool. Dual shield runs HOT and will destroy the standard mig gun in a hurry especially with c-25 gas. Co2 offers a little more cooling which can help with duty cycle. If it's just 1/4" material I would stick with 70s6 wire and c-25

I do a lot of similar work and use the 6" metabo with slide switch, 13 amp for the majority of it.

Corded metabo is the best I've used. I prefer a 6" as it's not a lot bigger than a 4-1/2" but much better performance. Cutting with a disc, the 6" gives a much better cutting depth and discs aren't much more expensive. As for cordless, the 20v DeWalt is fine for light duty work.

Lincoln 3350. First replaced the headgear this week after pretty much daily use . Bought it in 2018.

I prefer slide switch grinders and on the metabo ones I used have an anti kickback feature. I always use a guard which if I had to guess the OP wasn't.

9.5" angled head knipex

Not my experience.

Generally so but it gives a better " purchase" into the base material giving better prevention against stripping in the future.

Why not wrap a soaked rag around the fastener? Submerging seems like way too much effort for no gain.

In my opinion with indicators, your not doing actual measurements,your comparing straightness or concentricity. Inexpensive indicators can distinguish that difference almost as well as expensive ones. The shars brand work well and are about a fifth of the cost as the expensive ones. Save the...

I believe those are 14mm. Flare nut socket , might also be called an injector line socket. When replacing all the lines I just cut them with a large knipex side cutters and use a 6 point deep well.