CarlMc wrote:
What processes were the most common during wartime manufacture?
Regardless they were performed by PROFESSIONAL welders that could lay a nice smooth bead on all thicknesses of metal. The average "Hobbiest" will lay down a bead with a stick or flux cored Mig welder that looks like a row of chicken turds. On thinner metals they'll usually burn through several times and especially at the end of a weld where it approaches the edge.
A Tig welder is best as one can control temp as they go and even less expensive welders can do a decent job.
I was taught as a teenager by a WWII shipyard welder. I'm by no means an expert but I certainly wouldn't approach a Sten Kit with a buzz-box and sticks. A good Gas Shielded Mig or Tig setup. Shop around for a good used unit that IS NOT from Harbor Freight. Tig welders are extremely useful.