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Duker-inspired welding table build

kalthans

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Apr 17, 2015
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I've been meaning to start this build thread for some time, but am only now getting around to it. I'd been using a flimsy Northern Tool welding table for some time and needed something sturdier and truer to work with. I knew early I wanted something that had the ability to shift my vise and grinder off my workbench so I could free up that space a little.

Luckily I stumbled on Duker's welding table build. I was absolutely floored. It was like those moments in movies where the clouds open up and a shaft of sunlight bathes the object of your desire in golden hues. I will admit now that I immediately set out to shamelessly copy a lot of the features he incorporated into his table.

First and foremost I loved the way he incorporated vertical tool boxes into his table. I was on a bit of a budget, so instead of Mac I went with Harbor Frieght. My the space in my garage was limited...I'd be working with a top around 24x48 instead of Dukers 38x60. (it actually ended up being 26x48 for reasons i'll go into later). so I knew I wouldn't be able to bookend the bench with tool boxes.

I started by pre visualizing the layout in Maya. A fabrication specific software package would have been more appropriate (like Solidworks), but Maya is what i was most familiar with, so that’s what I went with. I tried using some engineering plugins for it so i could use standard steel materials as primitive shapes, but it was more trouble than what it was worth. In the end I found the easiest thing to do was to create a starter primitive shape of known size (in this case a one-foot long section of 2x2 square tube) and then clone & scale that as necessary to create the various dimensions required for the build. it was surprisingly easy once i got a lot of the scale multipliers memorized (i.e. a 1.5 scale equated to 18 inches, etc).

Here’s the layout i started with. The most notable design feature beyond all of Duker’s base features is the provision for mounting accessories around all four sides of the table. The two short ends of the frame have the 2x2 tubes spaced 22” apart. That same dimension is present on the interior cross sections that poke out of the long side of the table. This means any accessories I want to plug in (like the plasma table and cutoff saw) can be switched to any of the four sides. The 22” dimension was dictated by the width of the toolbox in the middle. (More pix to come of all this later).

I'm pretty far along in the build, but would love feedback and suggestions (be brutal, i can take it).

Once again, I can't give Duker enough credit for how inspiring his build was. Thanks so much for the expansive build thread and YouTube video.

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kalthans

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ok, here's the beginning of the layout. 2x2 tubing, .25 wall. I realize now that it is horribly overbuilt for the application, but i was making my decision on my ability to telescope a smaller size tube inside the 2x2 (in this case 1.5" tubing). i checked my local resources for a thinner wall pair of sizes that would nest and still hold hefty accessories like a vice or anvil securely. couldn't find any. would be interested in hearing what materials others have used for this type of application.

btw, that center crossmember didn't make it into the final design because i nested the top of the tool box inside that portion of the frame to reduce overall height

i-tNCKc8p-L.jpg


i didn't have a large enough surface to weld on (catch 22 when building a first welding table) so i simply laid down some extra stock to create as true of a platform as i could. checked level as best i could and it seemed to turn out ok as pieces started fitting together as planned

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welded up:

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ilovevocs

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Any plans for a tray under the cutting table side?

I am a proficient maya user. I like the level of autonomy and flexibility it has. It is however a tool that I only use for conceptual design. Beyond that I rebuild the model in another software package; I used to bounce around from some software packages depending what the project and output was. Rhino, solid works, and finally I just gave them both up and went to Catia. Personally I don't model allot of nurbs surfaces in maya. The true power of that package is polygon modeling / subdivided surfaces.

I also did allot of MEL programming unlocks the true power of the software. I used to teach MEL programming seminars when I was in grad school.

Im wonder what your background is that you were ever introduced to it. I am an architect by education and maya was the primary tool at graduate school. In fact my dog is named maya; im that kind of dorky I guess.
 
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tarbellb

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Great start, and yeah, .25" wall is crazy burly for this.

At least its not going anywhere!
 

longlivepunk

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Edmonton, AB, Canada
Cool! I loved Duker's build, I'm looking forward to seeing the finished product of your take on this. Are you planning on doing anything for a clamping system on the top? (Drilled, drilled&tapped, slotted, etc?)
 
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kalthans

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thanks, ilovevocs. When you said cutting table, did you mean the plasma side or the saw side? Yes, i plan on putting a tray under the plasma table. not sure yet exactly how that's going to be finished out. would be nice to have it as a swing-up section rather than having to insert it. definitely going to have it rigged so i can swap out chewed up slats.

tarbellb, yes...i really goofed on the 1/4" wall choice. it all rippled from the decision to have the telescoping inserts for accessories. oh well. if i decide to go heavier on the top i know it can take it. maybe a 100lb anvil too. the top i have now is 1/4" as well. not as thick as i wanted it to be (1/2"), but a manageable size for me to move around on my own without risk of back injury or missing toes. right now it is just going to be screwed in place with countersunk hex bolts. i've seen some **** tables made out of 1/2"x6" bars of steel to allow fixtures to be clamped internally. that's a nice idea that allows for manageable material handling during fabrication.

ilovevocs, it's a good thing you weren't crazy about Powerpoint. Stupid name for a dog. I know Maya from the VFX industry. i'm not a 3D guy by trade, more on-set, camera and supervision. I know enough Maya to get into real trouble. Having me work on your scene is like sending your best five guys on vacation.

Here's a pic of test fitting the toolbox before welding up the bottom portion of the frame....
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8man

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I just finished Dukers build and will be watching your build with interest as I'm going to be doing my own once I get into my shop. Thanks for detailed postings.
 

Duker

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Luckily I stumbled on Duker's welding table build. I was absolutely floored. It was like those moments in movies where the clouds open up and a shaft of sunlight bathes the object of your desire in golden hues. I will admit now that I immediately set out to shamelessly copy a lot of the features he incorporated into his table.
i-8TwQVPJ-L.png

I have to admit I did a double take when I saw the thread title. : )

Kalthans, I appreciate the comments. I would be remiss however, if I didn't acknowledge all those folks who built their projects before me that inspired mine. I am just glad that the build was able to inspire and help some other folks. It has been fun watching other folks put their own creative ideas on their tables. I am looking forward to seeing your build. The drawing and progress so far look great! :thumbup:
 
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kalthans

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thanks, Duker. I assume everyone on these threads draws inspiration from each other. Very thankful the community is so open and collaborative. Would love some input on mine when I get down to the finer details. I just wish I'd had enough space to build out a table to the scale you did. The space in my garage just didn't allow it, hence the inclusion of expansion on every side so my workspace can expand to meet the needs of my project without having too large of a permanent footprint.
 
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kalthans

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here's the top and bottom frames done:

i-trd55kM-L.jpg


and here's the process i used to get the best alignment possible working off the floor of my garage. there was only minor deviation for the floor level, so laying down extra 2x2 stock to use as a base gave me a pretty true reference. after that it was all a matter of measuring and clamping, tacking, remeasuring. i only had to break off one set of tacks because of something pulling out of true.

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and here's the frame sections combined. i ended up adding those corner gussets not for support but to accept the screws i was using to attach the top. i initially thought the screws were going to go through the frame, but once i got it built i realized they would interfere with some of the accessory mounting features i wanted to include. so i punted and pushed them inboard a bit to those gussets.

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in the end i got incredibly close to my target measurements...probably within 1/32"...which is pretty good for me. in retrospect the single hardest thing to get right was precise cuts on the 2x2 tube. without a dry cut saw i knew i'd be having this problem, so i got a nice big 12" disc sander from Harbor Freight to true up the ends of my stock. the price can't be beat, and it has enough power to not bog down when you press a section of 2x2x.25 up against it. the table and miter block are pretty crappy, so it is on my list to modify that eventually to be larger and more stable.
 
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kalthans

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ok, here's the latest. finally got a weekend off, and a ton of progress was made. i test-fit the toolbox into the frame. the blue tape was there to keep me from scratching up the finish. i had to grind down the inside of the frame a bit to give it a clearance...the tolerances were a little too tight.

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kalthans

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the top came next. i REALLY wanted to go with something beefy...like at least 3/8" or ideally 1/2"...but the lynchpin was my ability to wrestle such a thing myself. so i settled for 1/4" knowing it would serve my purpose and i could always replace it in the future (considering my base is probably rated for five tons).

was trying to figure out how to screw holes through it cleanly, and was wishing i had a magnetic base press. turns out a friend HAS one (thanks, Roy!) and was kind of enough to loan it to me. i can't tell you how sublime it is to use that bit of gear. the whole time i was drilling i kept visualizing i was breaking into a bank vault.

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maxpat82

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Dec 9, 2012
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Great, I need to build myself a plasma table like yours (bought my plasma machine 2 weeks ago)

I used 1,5" ,120 wall tubing for my frame.
1,25" slide in easy and is plenty enough strong.
My table is 2'x4' with a 3/8" top.(drilled every 6" since the picture)
I have built a brake out of c-channel already for it.
I can't put to much stuff under it since it's made to roll over my part washing tub.

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LG63

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the whole time i was drilling i kept visualizing i was breaking into a bank vault.

Same here. the first time I used a mag base drill I felt like I was on an old episode of Mission Impossible. The gear reduction sounds like it's a million to one.
 
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kalthans

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Finally got some time to work on the table. One of the primary reasons for building the table was to have a home for my new plasma cutter. I'd rather have the welder on this table, but the bottle just wouldn't fit, so i made a little shelf for the cutter underneath. my size guestimates worked out great...the shelf fit right between the rubber feet of the cutter and kept it from moving around....

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kalthans

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next up was the offset table for holding my saw. again, Duker's implementation was not only inspirational but damn near perfect, so I pretty much copied it outright. pretty genius design, Duker. it has already come in handy for a bunch of cutting.

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kalthans

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one thing i'm really looking for further inspiration on is how to organize and store my clamps. right now i just have a bit of bar stock clamped to the frame as a temporary solution while i feel out other options. My table is pretty small, so i don't have a lot of room for fancy hooks and such. I was considering some sort of extension to the table's frame that sticks out under the cutoff saw shelf...that'll give me some room to work. if any body has ANY ideas i'd love to hear them. please post pix your clamp storage solutions! (sorry for the ****** out of focus pic in this case. only one i had of this side of the bench)

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