Lawrence, doggone it, I forgot to make the necessary arrangements to pull all of those things off. But you have given me some ideas. Here after all these years, it takes a post from one my comrades in arms from halfway across the nation to bring me to see the light on some of these most important issues. I do sincerely appreciate this invaluable information. Thanks, Lawrence I'm enjoying the mental picture of seeing the look on my deans face while I'm carrying out these important and necessary tasks.

The only real "crack sensitive conditions in Colorado" are #1, when "the lab" in the hotel room next door to you blows up from some type of "mis-proportioning in the recipe" or #2, when the waist band of your "migratory longjohns" comes to rest at a position closer to your knee caps then your navel.  To this condition add a little north/south wind, some snow, a few warm welding sparks from the overhead full pen beam splice your working on from the very top rung of the ladder with your arms at full extension and you've got "Crack Sensitive Conditions."   At these times I wish those Tillman leather jackets had tuxedo tails.  The other crack sensitive conditions you speak have been easily overcome here with well developed knowledge and some skillfully applied technique.

Aspirate!!  On the issue of the defective stinger, are you for real?  If you are that hard up that you cannot get a new stinger together, then communicate to your boss the fact that the average price of a just a 4 1/2" hard wheel is about three bucks each and by your account you are using a couple or moe of these a day. repairing defective welds owing to the crappy stinger.   With that "revelation" even the stingiest Bozo of a boss can figure out that the cheapest Radnor or what have you brand stinger would be paid for in less then a weeks time with the  savings hard wheels alone.
Failing that attempt, send me your address and I will send you a stinger.  But remember this!  This time we will somewhat understand that the problem is your bosses fault.  The next time........... well that may be another story!
Learn this! There are basically two kinds of people in the world with regards to circumstances like these.  The first group known as Ninety-five percenters who have things like this happen to them and then moan badly in a poor me fashion, blaming everyone else for their problems.  The others are the remaining group of "Go-Getters" known as the Five-Percenters whom make things happen for them so crap like what you describe does not land in their lap.
As you can see this forum is full of people who make things happen for them.  Therefore it is easy to see that most here are of the five percent side of things.  Even Sourdough, on his current deployment in the waste water treatment aquarium, is making it happen in the most trying of circumstances.  Would not surprise me one bit if he figures a ways to make Bio-diesel from all the "discoveries" he had made there!  Not trying to belittle you or your situation but consider this; if your were intelligent to learn to weld as well as you claim, then you are certainly smart enough to figure your way to better in this circumstance.  I don't care if your boss welded pipe, plate, beer cans or even the crack of dawn together; if he is this much of an ignoranus then find a way to get him the heck out your way so you can move to greatness!  Welding/Ironwork is a trade made mostly of smart, crafty, inteligent, skilled people whom are very proud of what they do.  Weakness or inadequacy is not well tolerated here.  If you need help, then someone is likely to help you if you ask with some respect and maintain for yourself proper respect and dignity.  This trade, as well as the rest of your life, rewards personal excellence so go out and make some for yourself.  To get you started in the right  direction the stinger you need is on me.  Just get me the shipping information and the amperage range your running at. 
Regards!
XPERTFAB