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.023 to .030 depending on your welder settings, your preference and method (spot welding, plug welding or butt welding). It also depends on if you are using a shielding gas.

I would experiment with some scrap to get used to what you are going to do...
 

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I use .023 on panels. I agree with 67shelby, play with some old stuff first the get into the parts.
 

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Discussion Starter #5
I have the cheaper floor pans and using .30 wire. When I turn up the heat to bite in the side of the car where the frame is, it just melts the floor pan. When I turn the heat down so that it doesn't melt the floor pan, it doesn't penetrate into the car structure. Guess I need to turn up the wire speend and move a little faster.
 
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