Tig torch...

What sizes are the torches you are using, ntsqd?

The torch that I am using is a 17. Water cooled torches come in all sizes. 9, 17, 18, 20, 26, etc.

17, 18 and 26 are larger size head with their own set of consumables, while 9, 18 and 20 are small.

The size of the lense or cone makes access a big difference. 2" of stickout is massive. If you need that much depth, it sounds to me like the neck of the torch is getting in the way. A pencil type, flex head or a longer gas nozzle or lense is needed on the head of the torch. I can't imagine what kind of gas flow you would need and what kind of diffuser with two inches of stickout and still get a clean weld. The flow increase would cause a lot of turbulence at 2", even with a diffuser and would eat up a lot of gas.

I'm debating on getting a #9 torch with a flex or swivel head, for really tight areas, but I went with the 17 because of it's capacity to go up to 200amps, with my machine running up to 185, or 205 on helium.

If your machine runs up to 250amps, the head of that torch might be a little big for some of the sheet metal or chassis work that you are trying to do. Look into getting a second torch set for that thing, to get closer to your work and you will see better results in color, less porosity and scatter from better shielding and better control of the bead.

The more torches, types of cones/ lenses and tungsten as well as tungsten sizes you've got in your tacklebox, the better you can suit your welder to the job. There is never a perfect tool for every job and tig welding is no exception.