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Random thoughts:
Reading into your statement it sounds like you aren't prepared to spend a whole lot. That's fine, but the long and short of it is that unless you are really skilled with welding in general you probably want a TIG with AC squarewave to yield the results you're after, and really only after you've learned to use it with much practice. There are MIG units available that will do it just fine as well, but that gets spendy too and IMO the TIG is more versatile and controllable, albeit slower in some instances. What scares me is guys that want to weld aluminum trailer parts or heaven forbid structural members. #1 DO NOT buy a welder at Home Depot based on price, #2 Go to a welding supply shop and just ask a bunch of questions. It will be well worth your time.
For reference I have an air cooled TIG with AC squarewave; its a cheapy at $2k. However, I can run my heat range down to the point where I can weld pop cans together all the way up to 1/4" plate. In a nutshell AC frequency sort of bead-blasts the surface oxidation off of the aluminum, allowing a cleaner and more controllable weld.
You may find that if you plan to do very limited stuff you might find a custom car guy that will zip your stuff together for less dough...
Good luck!
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'84 Carrera Coupe
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