what is the rating of the machine?. here some basic.
the thicker the metal is the more pass you have to do with low amperage. grinding the edges off will help in a depper penetration of the welding rod and of course the more the amperage is the penetration will be depper and in this case the less passes is required. rod size is important with the amperage too.
Uh huh...I'm surprised that works without frying the alternators. Anyway, if they are in series, you have 24V @ 60A or so. Kind of small. My arc welder is a 70A unit, which I can comfortably use to weld 5MM steel with ample penetration. I wouldn't want to go any thicker.
i took off one alternato r because the belt was comming off a lot. they where wired in paralell. i tried to strike an arc at 12v 60 amps and it was easy. but doubt i am getting the full amperage out of the units, they are only being spun at 1000 rpm. i guess i could be getting 30 amps if i am lucky. ill eventually have 4 alternators belted to a faster motor. the alternator only sees the spark as a small load