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Welding Table/Workbench Build

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FULLSCALE302

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Apr 8, 2014
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First off I'm more of a reader than a contributor on here, but hopefully I've got something worthy of posting here!

I've been wanting to build myself a combination of a workbench/welding table for a few years now. To make a long story short, my father-in-law's friend bought a 5'x10' plasma table and my wife, who is a graphic designer, is teaching him how to design parts and things to cut. Her payment is time with the table to cut whatever she wants (pretty much whatever I want!).

I started off with this 1/2" table top that I drew up on Google Sketchup. It is 30"x74". The slots are 5/8" wide, I wanted 1/2 of the table to be able to clamp fully to and the other half a solid space to use as a workbench.



I wasn't able to get my hands on a mag drill so I got creative and lifted the top onto one of my tool cabinets and spaced it up onto square tubing so I could get the drill press table under it to countersink the bolt heads.



I couldn't get my Dormer countersink bit to do the job (not sure why!) but my cheap Princess Auto bit would chew right through it. The only problem was that it wasn't big enough to allow the bolt to sit flush with the top. Problem solved... I ground the head of the bolts down and drilled deeper with the countersink bit. I know it's not the proper way but with 8 bolts this 300lb plate isn't going anywhere!





Next up was building the frame below the top using 2x2x1/8 and receiver tubing with way more nuts welded to it than I will ever need.





 
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FULLSCALE302

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Legs were next on the list, I made some adjustable feet that stick out just far enough to clear the caster wheels but not far enough to trip on.









Here it is with the legs fully welded and the wheels and adjusters bolted on.



 
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FULLSCALE302

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I wanted a little bit of storage to I took another piece of 2x2x1/8" and cut it every 4" to create a bit of a curve. I used my new slots and clamping kit to hold it right where I wanted while welding it up.





It's tough to see in the pictures but the expanded metal is welded to the edge of 1"x1/8" flat bar and drops into the openings in the shelf. I haven't decided whether to weld them in solid or make them removable.



I had to clean up the logo my wife made (our last name) with some carbide burs as it was a little rough after plasma cutting.



This is where I'm at as of tonight. I need to find a way to get the mill scale or coating off. Any ideas? I think I'm in it for just slightly under $300 (the table top was completely free!).

 
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FULLSCALE302

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Thanks guys, very happy with it so far! I have a couple of those discs, I never thought of using them for mill scale. I've only ever used them for paint and didn't think they'd be strong enough!
 
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richeyc2000

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The curved feet and the curved shelf really complement each other nicely. Lovely build.
Can't wait to see it progress. Great work.
 
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EdT

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Very nice solution on the wheels for moving and the feet for working. I must have 50 sketches of ways to do that, but I didn't come up with that one. Now I don't have to. Simple, elegant, effective. NICE!!
 
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LXCam

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Wow that's very nice. Well thought out, well executed and well quite frankly would look so much better in my shop...hahaha.

BTW, you get triple points for the adjustable feet brackets!.
 
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Jack Olsen

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Looks great!

IMG_1350_zpsywbzesux.jpg


I like the curved piece, in part because it reminds me of a piece of my own bench.

outside-bench.jpg


Well done!
 
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txvwnut

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That's really nice right there.

You've just gone from lurker to contributor to someone who's design will be stolen and used on someone else's bench build.
 
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wrenchMONKEY_

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Jul 9, 2013
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Great table! Lots of good ideas. I've got a thread going on here and just picked up a 12x6 3/4 table that I've cut down.

Any more plans, grinder rack, clamp rack, paint?
 
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FULLSCALE302

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Thanks everyone, the comments are great! If anyone has any ideas on what else I should add let me know.

I had plans for a grinder rack but haven't came up with a good enough idea yet. I added the 5/8" rod below the top on three sides for hanging clamps.

As for paint, I plan on using Duplicator aerosol bedliner to match my welding cart pictured below that I build a few years ago.



 
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FULLSCALE302

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Just a little update... I started stripping the mill scale with a 4.5" stripping disc on my grinder. It works great, just takes a fair bit of time. I made it this far with one brand new disc and one that was already about 75% used up. I ordered a few more, hopefully they'll be here before the weekend so I can finish up.



Before on the left and after on the right.

 
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csp

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I started to do the same thing with the stripping discs and finally caved to using muriatic acid. Even with having to remove the flash rust that's unavoidable it was faster than mechanically removing the mill scale.
 
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wrenchMONKEY_

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Looks great!

I've almost finished my table to and I picked up a few strip discs, however, my surface has a bit of pitting on it and I am thinking that maybe the Acid route would be easier.

Mine is 4x6 so a bit smaller, but still, I did a 1sq ft section and I know how much fun I am in for.

Any more plans for the table?
 
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sbd4de3

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Sep 20, 2014
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Is there something that can be done to keep the top from rusting after you get the mill scale off? Would you coat it in WD-40 or something like that?
 
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FULLSCALE302

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I was finally able to get back at this bench, and as of this morning it is DONE. I didn't keep this thread updated with my progress, so here are a bunch of pictures showing it. I went through half a dozen stripping discs and a few hours to get the top where it is now, a state that I believe is cleaned up enough to look good but not so good that I'm scared to use it!

I used four cans of Proform self etching primer first.



I followed that up with four cans of Duplicolor aerosol bedliner.



I love the texture of it, hides any imperfections in the steel (and my welds!)



I wanted to try something a little different to organize my grinders... this is what I came up with. It's not the easiest to get them in and out but the one I use most is out front so it's not too bad. I think the compact storage outweighs the extra 30-40 seconds to unscrew and remove from the rack. It'd be different if I were using them every day though!





I bought a new vise too, one similar to the Wilton ATV but for less than 1/2 the price. I'd love to restore an old one, but this one suits my needs and my table better... and for $99.99 I can't complain!



Here are the rest of the pictures. It took me way too long to complete, but worth every minute to me. I love how it turned out and nothing beats being able to say I built it and there isn't another one quite like it out there.









 
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S4cruiser

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Sep 11, 2013
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Super nice! Think I'm going to borrow how you did the expanded metal for mine!!
 
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machine_punk

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Napa Valley, California
Well Done! Great design and execution.

I've spent a LOT of time thinking about casters and legs on shop equipment and benches (I like to have EVERYTHING on casters. Easier to clean and rearrange the shop to work on different projects). Your plan is pretty much the ideal that I came up with. Legs with leveling pads on the outside and casters on the inside.

The grinder rack is an interesting solution. I don't think it would work for me, but I'm interested in hearing how you like it, as you use it.

Great use of a plasma table, while you had access.

Looking forward to pics of future projects.

KDub
 
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zmotorsports

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FULLSCALE302 said:
Just a little update... I started stripping the mill scale with a 4.5" stripping disc on my grinder. It works great, just takes a fair bit of time. I made it this far with one brand new disc and one that was already about 75% used up. I ordered a few more, hopefully they'll be here before the weekend so I can finish up.

Click to expand...

Do you mind me asking what brand/grit of stripping disc you used to remove the mill scale. I usually purchase P&O steel so I don't have to contend with mill scale but my welding table also still has the mill scale on it and I would like to remove it. The couple of discs that I have tried, I have been less than impressed with.

Thanks.

Mike.
 
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