Bradness
CEG'er
Sorry its not a waste of argon or material to each his own. You have more control with TIG nuff said. I TIG all materials becasue it's pretty and strong. Too much spatter with MIG. And yes I know how to weld and set up a MIG welder.
I take issue with a number of your points. First, spatter can be caused by many things (too high current, for 1) and it's not inherent in gas shielded MIG. Don't know about you, but when I do MIG there's little or no spatter. Maybe you're referring to flux core/gasless MIG. Agreed that you have more control with TIG and it's pretty. Think of it this way... Your boss tells you do a job, but lets you decide HOW TO DO IT. You have 2 choices- 1 takes more time and costs the co. more $$$'s (in consumables). The other is quicker and less costly. Think you'd get a pat on the back, raise and/or promotion if you choose option 1 (TIG) or option 2 (MIG)? You may prefer TIG over MIG, but it's not the most efficient method for this job, plain and simple.
Josh: Even on the stock subframe sockets, the fuel line is very close and Ford puts a sheath around it. Now I don't know about returnless fuel system but I brought up the point to make others aware of this "issue". Of course it can be addressed in any number of ways.