When I have done it, I have used a Millermatic 250, ground the joints to a 45, and done a fillet weld, 2-3 passes. You don't need to move to a stick unless you are going to be going through at least a 1/4" stock. However, you need to have the 220v welders, the 110's simply don't have the power to penetrate through the thicker stock.
If the welder can not blow through the material, you should not be welding with that welder on that material. This is why I do not like to see anyone weld pipe, because few theatres have the welders that are meant to go through that much steel. .049 MT1010 box tube can be welded with just about anythnig, .2" pipe is another story.
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