I don't think I was very clear on what I have to work with and what I need for the result.
1. My 200 amp main panel is about 50' away (opposite end of building) and does not have an open breaker spot for a new circuit without re-wiring the panel.
2. The majority of the electrical wire runs were done in plastic pipe that was buried in the gravel before the concrete floor was poured. Most are either 1" or 3/4" depending on how many circuits were runs and the wire gage. All this work was done by a licensed electrican.
3. Some of the circuits are under utilized in the panel, having only one plug for example. When the building was built 25 years ago a plug and light on 2 separate circuits had to be wired in to allow the power company to hook up the service.
also, some lighting circuits have only 1 or 2 lights due to shop laylout at the time. The 200 amp service IS NOT over used, just not as efficient as it could be.
4. 12' from the RV parking bay I have a 50 amp 240v circuit for the Tig welder. This circuit is only used during a fab project, maybe 4-5 times a month at most.
5. My air compressor is located in the RV parking bay and has a dedicated 30 amp 240v circuit. I believe the pipe in the floor that serves this outlet also has a 20 amp 120v circuit for the RV bay. This is what I'm currently using for power to the RV. With this many wires in a 3/4" line I doubt there's room for any more wires there.
6. My RV has a 50 amp cord. 50 amps will run all of the RV circuits including the AC. I have a 30 amp to 50 amp adapter cord and a 15 amp to 50 amp cord. I've been using the 20 amp adapter which has been ok for charging batteries and running the fridge. I haven't tripped a breaker during the 6 months of using it this way.
7. I would like a full 50 amps so I can use the AC if needed (say for guests staying with us) but would settle with a 30 amp service. Even though the 15 amp service has not had an issue so far I think it is marginal.
Knowing all this it seems like using the welder circuit for the two 120v hot feeds and ground and then pulling an additional wire for the neutral would be the simplest solution to supply the RV bay. I can add a small panel near the welder plug if that is the best way to organize the wiring.
The only issue I see is if tried to weld at full power when the RV's AC was running. Something I can easily avoid as I don't work in the shop when it's that hot out anyway. Am I missing anything?