Welding equipment upgrade for thick aluminum

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I am currently manually AC TIG welding 6061 aluminum with a ’92 Syncrowave 350. A couple of times a year I will have some thick weldments that I have to tackle (32″ dia plate, 1/2″ thick; with an 11″ dia tube 3/8″ wall x 60″ long tube welded in the center. Then I weld 8ea triangular gussets which are 3/8″ thick, 10″ x 20″.) ~650″ of weld bead per assembly

With lots of preheat, AC Balance up high, patience and 75 helium 25 argon
mix, (straight helium gives me too unstable of arc)I have been able to accomplish two of these weldments so far with the Syncrowave 350.

I have been looking at upgrading equipment My welding distributor is really trying to push the Thermal Arc Pro Wave 400 which has 470A max output.
I have heard from some that the inverter power sources are getting more reliable than they used to be, but are still can expect to fry boards on the upper amperage end, even if you stay within the duty cycle.

1. Are there any significant reliability problems with the bigger GTAW inverter power sources of today and in particular with this model?
2. What other Machines are there to look at in this amperage range? (I only have 1 phase power but have rotary phase converters from 7hp to 20hp if a 3 phase machine is the only logical choice)

I am also considering a pulse MIG system such as the Lincoln Powerwave 450 with an MK wire feeder. Once again my dealer is insisting on a Thermal Arc powersource and pulser with the MK gun. Any suggestions?

(good looking weld beads with minimum cleanup is quite important)

Thanks in advance for your help,

-Raimo

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