Dukers - Welding Table Build

[Duker]

Welcome to my welding table build.

First, let me start off by saying I never really intended to build a welding table. You see, the problem/project started when I made the mistake of looking at the VISES of Garage Journal thread and became enamored with all of these great vises GJ members had collected. I never knew I needed a Wilton vise but now I have one. In fact it has been one of the best buys I made off of GJ. Well, the sickness grew and not long ago I found myself searching for another vise and I came across this monster. A Rock Island 597. Did I really need another vise? Did I really need something so big that it gave me a hernia loading it in the back of my truck? Well of course I did and I have learned not to ask stupid questions.

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Did it look this way when I found it? No…. of course not, through my now incurable illness I learned that you need to restore it and paint it to match your garage color scheme. So I did, you will be able to find those before and after picks in my Garage Projects thread when

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I posted them here if interested:

url]http://garagejournal.com/forum/showthread.php?t=100158[/url]

So how does all that relate to building a welding table you ask? Well, the question was now where do I put the vise…. And that’s how it began….

The original plan was for the top to be around 3’ x 4’ x ½”. However, when I went to my local steel supply they showed me a piece 38” x 60” x 5/8” at a fraction of the cost so I bought the piece. Here is the top.

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In the midst of sandblasting…

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Included in the base will be two side cabinet tool boxes. One will hold MIG and the other TIG supplies as well as clamps etc.

I already had a Matco side chest that I have been using on my HF cart but I found another Proto on Craigslist that was too cheap to pass up. The box had a ding in one corner and had the top edge ground off for some reason but for the welding table it would be perfect.

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Due to the size of my shop I needed the table to be mobile but I wanted something that was still solid enough to pound the living daylights out of something and not move. A friend of mine built an assembly table using these casters from Caster City and it is rock solid so I went with these.

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I am using the top propped up on some saw horses to build the base. Here is the one of the bottom units to hold the tool box.

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Here is how both boxes will be positioned:

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My welding leaves a lot to be desired but I thought this would be a good project to build my skills. As you can see in the photo below I am still a long way away from a “stack of dimes” but I think I am getting good penetration. I am open to all comments if you see something that could help me improve.

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In the next update I hope to have the following done….

I will have 2” x 2” rails between the two sets of legs top and bottom that will also have stretchers that go across to support the tool chests but also some expanded steel I will use in the bottom.

In the top I will build a slide out rail to hold long pieces while cutting with a dry saw that I am going to incorporate a mount for into the base. I will also have built in “trailer” type mounts into the top rails to hold a grinder and assorted other tools.

 

[fourjeepin]

Looking good!

 

[machine_punk]

I like the idea of using end boxes for storage of supplies. I've only been welding for a short time and only with one process so far...and I'm thinking I could eventually use a whole tool cart (like the 5-drawer HF cart) just for welding supplies, eventually.

Looks good so far. It looks like the boxes are going to be pretty well protected, but have you designed anything specific to keep grinding sparks out of the drawers (I don't see a lot of folks put drawers on their actual welding/fab tables...I suspect that is to keep stuff clean/prevent sparks and fire in stuff).

Kev

 

[Duker]

Thanks Fourjeepin, it has been a fun project so far.

 

[Duker]

Thanks Kev,

When researching welding tables I found a load of pictures with varying designs using built in storage which is how I came up with my design. In fact there are some great GJ tables that I have "borrowed" features from and incorporated into my design.

In regards to protecting the tool boxes from sparks, I honestly don't know how its going to work out. I am positioning the boxes so that they will face out each end for the reasons you stated as well this will allow me to run the 2 1/2" square tube from end to end for my cutting extension as well as use the other side to mount the dry cut saw at the table height.

Since I plan to do most of my grinding on the table top usually across the width of the table I am hoping that this will deflect most debris away from the drawers.

If you see anything else that may be an issue please throw it out there because its a work in progress so plans can change...

I like the idea of using end boxes for storage of supplies. I've only been welding for a short time and only with one process so far...and I'm thinking I could eventually use a whole tool cart (like the 5-drawer HF cart) just for welding supplies, eventually.

Looks good so far. It looks like the boxes are going to be pretty well protected, but have you designed anything specific to keep grinding sparks out of the drawers (I don't see a lot of folks put drawers on their actual welding/fab tables...I suspect that is to keep stuff clean/prevent sparks and fire in stuff).

Kev

 

[JonBoehman]

Sounds as iff you have the same GJ sickness I have developed. Lol! Great build keep it up.

 

[Duker]

LOL, thanks Jon. The only cure I have found is lack of cash flow but its proven only temporary as once a month right around pay day I feel the fever coming on....

 

[ilovevocs]

LOL, thanks Jon. The only cure I have found is lack of cash flow but its proven only temporary as once a month right around pay day I feel the fever coming on....

So true. I am fairly certain that tools are not chemically addictive but.....



On the vise / "vice", that thing is a MONSTER! I love it, nice work!

 

[Rezarf]

This looks great man, I am going to follow your progress as I am in the same boat of fabbing up a welding table/station.

 

[LG63]

Looks like a great plan. That plate on the sawhorses would make me a little nervous. I think I'd throw some tires or something under it to keep it from dropping all the way if something were to shift the wrong way. Maybe the horses are stouter than they look.

 

[Duker]

It does make a little nervous as well...

The saw horses are Crawford saw horses and each is rated to 1200 lbs so theoretically they should hold and so far so good. The base is pretty solid but I was afraid of rocking so I cut some plywood which is jammed between the legs underneath the top of the saw horse.

However, I am trying to be conscious to keep my feet out from under it when working on it as my reflexes are not as good as they once were...

Looks like a great plan. That plate on the sawhorses would make me a little nervous. I think I'd throw some tires or something under it to keep it from dropping all the way if something were to shift the wrong way. Maybe the horses are stouter than they look.

 

[Duker]

I was able to spend a few hours on the welding table project today. Not great progress, but it is starting to look more like a base to a welding table.

I was able to cut and weld the top pieces as well as cut the sliding sled square tubes which will be on the inside of the legs.

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I finished the tool box bottom mounts and welded them to the bottom cross pieces.

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Here is a shot showing how the tool boxes will sit facing out at both ends. There will be a piece of flat bar going across where I removed the key lock and name plate.

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In between the tool boxes and the cross pieces I welded some 3/4” square tube that will eventually have some expanded metal to hold my dry cut saw.

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Hopefully I have left enough room to mount a removable tig pedal holder that will fit the front bottom rail.

In the next update I hope to have the sliding sled tubes welded as well as the end cross pieces welded up.

 

[TerryH]

It's looking great!! Love the storage ideas, expecially the dedicated spot for the saw.

 

[Duker]

Thanks Terry,

Due to the size of my shop I am having to get creative in my storage as I have my welding supplies, clamps etc scattered everywhere. I am hoping this solves my current lack of organization.

I am also looking forward to not having to build future projects on the floor as I have done in the past.

It's looking great!! Love the storage ideas, expecially the dedicated spot for the saw.

 

[Jagmandave]

Will your gas bottles fit underneath too? Or do you have another plan for them?

 

[BJ42LX]

Duker, Nothing wrong with that weld. Better than some "pro" stuff I've seen on on mass produced tools and equipment...

 

[ADSR]

looks damn good!

 

[alpinewhite]

What kind of blade is that? It doesn't look like an abrasive blade? Diamond?

 

[Duker]

Jagmandave,

Interesting you mentioned that idea. I thought about that concept for a while but I decided to go with a separate cart that will hold both my Lincoln 180 Mig and 225 Tig (which I recently got but have yet to use.) I decided to go the cart route as I have found myself many times rolling my current HF Mig cart out in the driveway to weld as well as help friends with their projects and I think the cart will give me the most versatility.

I believe I have most of the design details for the cart worked out in my head. I have incorporated quite a few of the ideas I have seen from carts posted here in the GJ i.e. dual tank rack, tig rod storage, extension cord built in with 120/240 plugs, fire extinguisher etc.. The mobility of the cart is why I decided to have a removable Tig pedal mount as it would allow me to place it anywhere around the table to have better access to whatever I may be working on. In fact, I already bought the casters so this may be the next project in line depending upon what the boss (my wife) has in store for me next.

Will your gas bottles fit underneath too? Or do you have another plan for them?

 

[Duker]

BJ42LX,

I appreciate that. There are a few welds however, that prove my rookie status and would be more at home on Harbor Freight specials.

Duker, Nothing wrong with that weld. Better than some "pro" stuff I've seen on on mass produced tools and equipment...

 

[Duker]

Thanks LORDDiESEL! I am having a blast working on the project.

looks damn good!

 

[Duker]

Alpinewhite,

It is a Tenryu PRF-35572DK 14-Inch 72T Carbide Dry Cutter Blade. It leaves almost a polished edge when cutting mild steel. So far it has been the best blade compared to the original Milwaukee and Freud blades that I have tried.

What kind of blade is that? It doesn't look like an abrasive blade? Diamond?

 

[Responder]

That is looking really good! Can't wait to see the finished project.

 

[Duker]

That is looking really good! Can't wait to see the finished project.

Thanks Responder, I am hoping a couple of more weekends and it will be ready for paint.

 

[PhantomEB]

The end boxes are a good idea there.

I gonna use a Craftsman top box underneath mine, tucked up high as possible for more floor space.

 

[Richard D]

Alpinewhite,

It is a Tenryu PRF-35572DK 14-Inch 72T Carbide Dry Cutter Blade. It leaves almost a polished edge when cutting mild steel. So far it has been the best blade compared to the original Milwaukee and Freud blades that I have tried.

Is that a standard Milwaukee abrasive cutoff saw with a dry cut blade added?

 

[Duker]

Is that a standard Milwaukee abrasive cutoff saw with a dry cut blade added?

Richard,

The saw is a Milwaukee 6190 dry cut saw. It is a slower (1500 RPM) saw that produces much less spark and a much better cut than my old abrasive saw. The blades are not cheap but with some shopping on eBay you can find some good deals.

 

[Richard D]

I recently bought a new Milwaukee abrasive cut off saw and was pretty under-whelmed. Didn't seem to work much better the the worn out china saw it replaced(maybe the "Made in China" on the label had something to do with that.)

 

[Duker]

Richard,

I can relate as my old dewalt abrasive saw was underwhelming as well. I was looking for an alternative and the dry cut saws seemed to offer the features and speed of cut I was looking for in a new saw. After reading reviews here and on other forums I bit the bullet and bought one. It did the job so well that I sold my abrasive saw. You might check out the Rage dry cut saw as I have heard good things about them as well and they seem to pop up on sale quite often.

From my limited experience, if you cut a lot of thin wall steel I think the dry cut saw is tough to beat.

I recently bought a new Milwaukee abrasive cut off saw and was pretty under-whelmed. Didn't seem to work much better the the worn out china saw it replaced(maybe the "Made in China" on the label had something to do with that.)

 

[Richard D]

**** I wish I'd seen that Rage Evolution saw, I would have bought it instead.

 

[willymakeit]

Are the casters well protected? I seem to have flat spots on mine from hot steel and sparks. I mthinking of changing to steel casters.

 

[Duker]

Are the casters well protected? I seem to have flat spots on mine from hot steel and sparks. I mthinking of changing to steel casters.

Willy,

Good question, I may regret using these over the long term. A friend of mine built an assembly table with the same casters I will be using on my welding table project. That table is moved across rough concrete in a shop filled with metal and saw dust shavings and the casters seem to be holding up well. Hopefully these will last.

 

[racingtadpole]

From my limited experience, if you cut a lot of thin wall steel I think the dry cut saw is tough to beat.

I cut a lot of uni-strut and cable tray at work and now that we have both friction and TCT saws available for use in our store, I wont ever book out a friction saw. A couple of the guys I work with dont like them because they keep mutilating the cable tray with it, but thats got way more to do with them using a 30T blades instead of a 90T blade and not clamping it properly.
They are one of mans 10 great inventions as far as I am concerned.

Nice work on the table, I like the place for everything/everything in its place type thinking.

 

[Duker]

Nice work on the table, I like the place for everything/everything in its place type thinking.

Thanks, the size of my shop is forcing me to be more judicious with my work surfaces and tool storage. Is has been a good project just for the fact that I have had to think through future projects like a welding cart where I will be combining my mig and new tig machines just to save floor space.

 

[Richard D]

a welding cart where I will be combining my mig and new tig machines just to save floor space.

I'd think twice; I built a heavy-duty cart with my 220v MIG, plasma, and oxy/acetelyne bottles on it. Nice 5" casters. Was so heavy I dismantled it almost immediately. If you don't plan to move it much, maybe O.K.

 

[Richard D]

Hey Duker I just realized you are in Houston, what part?

 

[Duker]

I'd think twice; I built a heavy-duty cart with my 220v MIG, plasma, and oxy/acetelyne bottles on it. Nice 5" casters. Was so heavy I dismantled it almost immediately. If you don't plan to move it much, maybe O.K.

Hey Duker I just realized you are in Houston, what part?

Richard, I live north of Humble.

In regards to the cart, I was wondering if the weight might be a factor. i made a plywood cart that could hold about 10 sheets of mdf that has the same casters I was planning on using for the welding cart. When loaded up it took a little effort to get started but rolled nicely across some ridges and gaps i have in my driveway. That said i have not measured the weight of the welders and the steel so i may have to rethink the idea if it will feel like I am pushing my truck around with the brakes on!

 

[Duker]

I was looking forward to getting some work done on the table today but had a small set back that turned into another quick side project.

I had to clear some space so I was pushing some equipment out of the way to make some room to work on my welding table. As I was pushing my HF Sand Blast cabinet out of the way, I collapsed/twisted one of the flimsy legs. I decided that since I had the welder and saw ready to go I would whip up a new set of four legs with some casters to make it mobile to make it easier on myself in the future.

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I took some angle and cut it to length and used the old legs as a pattern for the screw holes.

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I added some ¼” for the caster base plates. I added two fixed and two locking swivel casters I got from Woodcraft. I rushed the painting and it shows as the color is not quite right but hopefully I can circle back to that later on.

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The blast cabinet ate more time than I planned so I decided to work on some of the little details of the build. I was able to get out my recent birthday toy, which was a Hypertherm 65 plasma cutter. I have to admit I amazed at what this thing can do and I find my self wasting time just looking for things I can cut up.

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I had not tried the expanded metal setting yet so I thought this was a good as time as any to cut up the piece that was going to be used where I am going to store my Milwaukee saw. I trimmed off the end to square up the piece.

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In less than 2 minutes I had the piece cut.

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I then went to work on cutting the slots for the cutting table extension. The slots are for a bolt that will be in the siding tube to keep the extension from coming out of the primary square tube as well as having a knob where it can be locked down to remove some slack. I drilled a ½” hole at each end of the square tube then ran the plasma cutter between the two holes to cut out the slot.

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I finished cutting the rest of the parts and ran out of time so hopefully tomorrow (in between honey do’s) I can actually get some welding done.

 

[TerryH]

Nice fix on the blasting cabinet! Bet you won't twist those legs. I'm jealous of your plasma cutter. Looks like a super handy machine.

 

[Duker]

I'm jealous of your plasma cutter. Looks like a super handy machine.

Terry,

I have wanted one for a long time. I spent two years buying old woodworking equipment refurbishing it and selling again to save up money for the "tool fund." When my wife asked what I wanted for my birthday without having to empty the fund it was an easy decision.

Besides being just a blast to use, it has opened up the possibility of projects I might have normally skipped because of being labor intensive to cut.