Mike,
I have an Excel Spreadsheet that will compare the cost of any two processes.(SMAW,FCAW,GMAW,SAW, GTAW) Weld joints include, Fillet, single-V, Double-V Single Bevel, Double Bevel, Compound bevel.
It will calculate how much time is required, how much wire, gas , and flux, it will show you how many bottles you need if you are using gas. It will break down how much labor cost, wire cost, and gas cost.
You can even change between English and Metric units. I tried to send it to your e-mail but it would not go through.
Let me know if you are interested.
Also, A spreadsheet that was written by Mark F Mruczek is on my website for download at http://www.weldinginspectionsvcs.com/weldCostExcelDownload.htm
This program is the way to go if you have excel. It has much more detail than the one I referenced above.
Good calculatin
G Austin