Yet another welding table build....

[wrenchMONKEY_]

Decided to start a new thread instead of putting this in my flat/slat thread.
**** or get off the pot as my grandma used to say.

I finalized the deal on the 12'x6' 3/4 thick table. Seeing as how the 8x4 1/2 plate I was going to go with was going to run me $350 at the lowest, paying $440 for this table seemed like a no brainer. That's Canadian money BTW, so about $2.50 USD after currency conversion.

The 6 "legs" if I dare call them that, are 8"x8" 3/8 thick. Shes a solid girl, that's for sure. The plate is about 2200# and the legs are about 100# each, so Id call it 2800#ish.

Also in the deal I got a new UniWeld Argon Flowmeter, bunch of Walter sanding and cutting discs along with a bunch of Weldcraft gas lenses and cups and collets ect ect. I was happy.

So, as much as I'd love to have welding table the size of my car in the garage, it was a bit over kill and the wife was a hard sell. I decided to cut it up into 3 pieces, each measuring 6x4, keeping the best for myself and selling the other two. The legs would be cut up into 8in wide strips for some poor mans flat bar and scrap the rest.

I took the truck and trailer up to work. My Miller 375 was not up to the task of cutting this plate in half, nor did I want to pay someone else to do it for me. I was going to use the Plasma at work, but apparently the plug on the Plasma is a 600V 30 AMP and all I could not find the adapter to 600V 20AMP which is what was on the wall. Oh well.

I wanted a clean edge, so, out came the Milwaukee Metal Cutting Circular Saw!
After cutting fine for the first 15 inches, the saw started to slow down HARD and kept kicking the thermal overload. Blade was roached. Off to get a new blade. I was going to just get one, but I got two, and I am happy I did. $100 and two 50T metal blades later, we were back in business, and flying! If from the start I had used one blade per cut, I'd of been at 15 minutes per cut, more or less. Thats 48 inches per cut of 3/4 plate. That saw is a beast. I am happy I did this at work, because the plate and trailer would not fit in my garage, so I'd of been doing this outside from 7-12PM, and since I had to return the borrowed trailer tomorrow morning, I am glad I could make as much noise as I wanted at work.

Everything cut down, sweaty, dirty and tired, I went home and went to bed. Work up this morning and go back to business. Now I had to get the plates off.... I decided on pulling them sideways off the trailer, using the truck and using 12' long 2x12's to act as ramps. An hour later I was done. And not a moment to early too as the garbage guy was coming down the alley and I had to move the trailer!

Pretty clean cut. I was very happy with how well the saw cut it.

This picture makes the table look really small. Perhaps the 8x8 legs throw off the ratio.

Going to use 2x2 3/16 square for the frame. Why? It was free. Standard rectangle top, 2 braces inbetween to support the plate. Frame will be pretty standard but will feature a kickout inwards so I can get under the table to TIG.

Gonna start working on the frame tomorrow. Should take a few days, then pay someone $50 to show up with a Mini Excavator to mount this sucker and I'll be happy. Then I can start the project list.

 

[f150skidoo]

That's a hell of a deal for all that steel.

 

[Know Wosad]

That right there is what the Milwaukee is meant to do.That's the only reason I unbox mine. To make little ones out of big heavy plate.Run it on the heaviest cord you can get.

 

[wrenchMONKEY_]

Started off in the morning picking up some new roller stands for the band saw. Long overdue. Happy with the quality for the price. A necessity for handing the 24' lengths of stock.

I was going to frame up the base on the floor in my garage, but after fighting with the un-even concrete floor for 10 minutes, I just took it outside and did it on the plate.

Added some center supports, but, as I found out later, they were poking past the outer frame and when I flipped the table over, I noticed my two center cross members were not flush. So I ground them out, cleaned up the welds and as you can see in the last picture, made sure they were flush while the table was upright.

Started cutting and adding the legs. Table should end up between 43-44" depending on how high the leveling legs are set. I am 6'4 so I am pretty happy to have my first workbench/welding table that's sized properly for me. When I flipped it for the first time I was almost in shock as to how tall it was. I even thought about cutting it down for a second because it seemed so "un-normal" but after using it to grind down the cross members, I was enjoying the height.

You can also see my new Lincoln Viking 3350 helmet that I picked up. Big improvement over my lower end Lincoln. Viewing area is huge and the head gear is fantastic.
Also seein the background is the welder for the job. Using a Miller 211 with S-6 .035 wire and C25.

and this is where I called it quits for the day. As you can see, I had the clamps out to help flush up the top frame cross members. Got them tack welded in again and everthing is flush and square.

Tomorrow I'll finish up working on the frame. I was planning on doing one bar at the lower rear and then two 45's and a center piece of front to have a nice notch for sliding under the table for TIG, but since this table will be floating in my garage and can be worked at from all 4 sides, I may just do one center cross member to make it look like an I.

Also, I had no idea how I was getting this top on my bench. I was going to rent a mini excavator to lift it, but hiring it out was going to be cheaper. Today a guy came by to quote me. Instead of cash, going to trade him some labor to help him replace some teeth on his bucket. Also, he gave me a small OxyAcetalyne torch kit that he no longer needed. Victor guages, bottles ect. Pretty happy about that.

Come Monday, I'll pick up the casters, the leveling feet and then should be able to finish it off.

 

[wrenchMONKEY_]

More progress today.

I did alot of reading and soul searching (re: test fitting myself) and I kept coming back to feeling that 45" height for the bench was going to be a wee bit to high for me, even at 6'5. I spent a bit of time figguring out my leveling leg plan and how I was going to implement that. I was going to go Acklands and spend $25 per on some fancy swiveling doo-dads, but, knowing I had some 1" diam bolts that would work perfectly, I decided to save the money.

First order of business was cutting the legs down. I decided to take 3 inches off.
That should set the table at around 41.5 and have the ability to go up 2 inches using the 1in diam 3.25OAL Grade 8 bolts. Bit overkill, but whatever.

Picked up some 2x2.250 flat bar, cut into two inch chunks, 1 1/8 hole saw in the drill press, and you get this.

I also decided that this would be a good practice get some more TIG practice in instead of using MIG for the nut. While no one will ever see it when its built, I'll know!

Still not a pro, but getting better I think.

I made the first leg, and I made a bit of a mistake. The numbers for the height of the table take into account the nut is inside the tube, not outside. Not sure what I was thinking, but I'll just cut it off and pay the penalty of wasting 1 in of tube. I like the asthetics alot more of the nut inside the tube.

So tomorrow I'll finish up all the legs and go pick up some casters. Going to go with 6 in steel, poly coated, rated 1000# each. I'll be going with 4 swivel so it can move on any axis. Once I have the mounting height of the casters, and I get all the legs back on, I can start cutting and framing the lower supports.

I picked up some 1.5x1.5x.125 that I'll use to gusset each of the top corners, so thats also to come.

 

[wrenchMONKEY_]

Had a problem with my image host, changed over, hope all is well now.

Got another few hours on the table. Got all the leveling leg caps welded onto the legs and then welded them to the frame. If I were to do this all over again, I'd of gone with a bigger tube for the legs, but since that metal was free, it is what it is. The issue is, the diameter of the nut sitting on the top plate, when TIG welded on, the edges of the weld hit the inside of the tube, keeping the the 2x2 cap plate to sit flush on the tube end. Not a big deal, just ground the edges of the TIG weld it a bit down and had a few small gaps to fill. If I were to do it again, a 7/8 bolt would of done the job and alleviated the problem. Anyways, thats half the fun of these projects. Learning things as we go along.

Got the new revamped legs put on. Very happy with how it turned out. Today while I was at the caster shop, I priced out swivel leveling legs. $50 each without the stem! No thanks. I'll take my free 1inch bolts thank you very much!

Started cutting up the caster mounting plates. Used some of the 6in x 1/4 flat bar that was on the original table.

4 plates cut up and a bit of smoothing with a 7in grinder and flap disc. Maybe not CNC Plasma crisp, but, they will work just fine. I'll drill mounting holes and go pick up some bolts tomorrow morning. Also pictured are my 6x2 1000lb Phenolic casters I got today. I was going to spring for locking, or steel/poly, but for the extra 10-15 each, and for the amount of time that this thing will be on wheels, not worth it for me.

I actually started this part first thing in the AM. I cut the side/rear cross members, but, without knowing the exact mounting height yet (factoring in the casters + mounting plate) in relation to the leveling leg feet, I just decided to wait till I knew exactly. I know that around 8 1/4 should work fine, but I'd rather have it perfect to take full advantage of the min/max height my leveling legs can do.

Thats all for the day. Should be able to get the casters mounted and welded on tomorrow along with the rear support frame. Then I'll start doing the front bump out (where my legs will go when sitting on the stool) and then box that in. and the lower frame will be completed. Then I'll gusset all the corners with 1.5 1/8 thick tube, then weld the whole thing up.

 

[wrenchMONKEY_]

Today I got the casters mounted and finished the lower frame support. Also, got the table completely welded up. All the checking paid off as I am a little less than a 1/16th out of square anywhere I look. Good enough for what I am wanting to do. On a side note, the frame rolls beautifully on the swivel casters and the leveling feet work just as I wanted.

Used a ratchet strap to keep the table from warping while I welded it. While I did practice a few uphill vertical MIG welds, for the majority of the weld up I flipped it around on the floor to get a workable angle.

Angle grinder and 7in wire wheel made quick work of all the inside corner joint prep.

The obligatory show your weld shot... far from my best, but happy to say that's about as bad as it gets now.

Tonight I finished cutting the two front cross members for the bump out, then I'll finish up the bottom and it will be good to go.

I am undecided if I'll be gusseting this thing anymore. I don't mind using the 12ft of 1.5x1/8 tubing, but I really just don't see the need. Any thoughts on this? Id gusset all the top corners where the legs meet the top frame, and then I'd put two on the caster supports incase I have to wheel around something super heavy. I'd probably use a 1 ft length. The top weights 750# and I don't see anything more than 500# going on top. Any thoughts are appreciated!

 

[wrenchMONKEY_]

Started off the day by finalizing the lower frame. Used the two milk crates and cushion to simulate my stool height and making sure the foot pedal for my TIG is in a natural and easy to work spot. Everything worked well. I cant wait to sit at a proper table to start welding.

I knew I wanted to utilize the hitch receiver method for mounting vises, grinder stands and any other doo-dads I may want. I didn't want to use a hitch pin, nor could I with my mounting location, so I went with some 5/8 bolts and welded a nut onto my 6in hitch receivers. Funny, these things come with a nice black wrinkle finish, almost a powder coat, but being designed to be welded on, most people are just going to grind them down? I guess bare steel would rust while in storage. Anyways, got 4 turned out in pretty quick time.

Always happy to have a chance to practice my TIG skills. Two zaps with a MIG would of done the job, but, where is the fun in that? Pretty happy with how its coming along. I was only able to weld two flats before having to spin the hitch and re-position. I see why people have rotational helpers.

And got the 4 vise/tool mounts welded up along with the lower frame all welded to.

So that pretty much has the whole frame welded up. I wanted to get the vise/tool mounts welded on before the top plate as I would not be able to get the top weld, and IMO the most important one for such a short piece of tube.

Tomorrow I'll finish up the grinder / clamp racks, mount my 4 gang 15AMP power outlet box, cut up my 13ga expanded steel for the floor and get the top lifted on near the end of the day.

I've decided not to gusset the top corners, but instead,using the design I have in mind for the camp racks on the corners, should provide a bit of extra ridigidty that I won't have to worry about it. Even so, if I do, I can always add them later, the top won't obstruct any welds Id need for that.
After that I see a respirator, googles, iPod/earbuds, earmuffs and a bunch of strip / flap discs to clean up the top along with a few hours of my time.

 

[txvwnut]

Looking good. You gonna bolt the top to the base or weld it?

 

[wrenchMONKEY_]

For now probably just 4-6 small tack welds to keep the plate from shifting. I have not had the plate right side up in a while so I'll have to see how much work the surface needs and if the plate has any low spots in it.

Eventually, I'll probably drill a grid pattern for clamps and bolt it to the top, shimming/adjusting if needed.

 

[sbd4de3]

Great score on the plate brother! Was that a craigslist find? Good looking work on the table too!

 

[Justanoldguy]

That's Canadian money BTW, so about $2.50 USD after currency conversion..

US$2.50 is a real bargain. I didn't realize how worthless CAN$440.00 was.

 

[1/2 Cup]

Now that's nice, real nice in fact.

Great welding skills for sure, I could learn a lesson or two from your craftsmanship sir..

Regards

 

[FunkyfullWidth]

US$2.50 is a real bargain. I didn't realize how worthless CAN$440.00 was.

I heard they have a single coin for that amount...

That table looks great! I like how your doing the base for your feet.

 

[pepi]

Nice build well done .... thanks for the Milwaukee Metal Cutting Circular Saw demo. That is very impressive it will cut a chunk of plate like that, and so clean.

 

[wrenchMONKEY_]

Great score on the plate brother! Was that a craigslist find? Good looking work on the table too!

I got it from the same guy I picked up my Miller 211, 375 Plasma and Syncrowave 200. This table was from a company that went out of business and were bought out. I actually went to him first as he had 40 ft of 8in wide 3/4 flat bar that I was going to turn into a slat table, but, soon found out about the two tables he had.

US$2.50 is a real bargain. I didn't realize how worthless CAN$440.00 was.

Once upon a time it was worth more

Now that's nice, real nice in fact.

Great welding skills for sure, I could learn a lesson or two from your craftsmanship sir..

Regards

Thanks for the comments. I've only been at this a few months. Got my first welder in March of 2016 (4 months ago I guess?) which was a Hobart 140. The upgrade to a 220V unit ( the Miller 211 ) was a huge upgrade.

I heard they have a single coin for that amount...

That table looks great! I like how your doing the base for your feet.

Thanks! Lots of good ideas on the web about tables. I've borrowed a few and made a few of my own ideas so its a happy blend. I am happy with how the feet/casters turned out. I also enjoyed saving a bunch of money on using the 1in bolts instead of industrial machine style leveling feet.

Nice build well done .... thanks for the Milwaukee Metal Cutting Circular Saw demo. That is very impressive it will cut a chunk of plate like that, and so clean.

I was never planning on using it, however, I was watching ChuckE2009's videos on YouTube where he reviewed the saw. I think he was cutting some 1/2 or 5/8 and said it cut like butter. So I figured I could probably get it to choke through 3/4. I've actually got a few more cuts do do. I'll be turning one of the slabs of steel into a table for a customer. He just wants the 4 8x8 legs welded on so I'll flush up the cuts and stick them back on.

 

[APEowner]

Well, ****! Now I'm going to have to buy a Milwaukee Metal Cutting Circular Saw.

Nice table build. I look forward to seeing the finished project.

 

[wrenchMONKEY_]

With all the big stuff done on the table I took today to work on some of the small stuff.

First thing I wanted to get done was my clamp racks. I am going to have 3. One on the left and two on the right. The one on the left will be for my Bessey 12 and 24in clamps, long reach Vice Grips and C Clamps. The two on the right will be for the KantTwis clamps, 11SP ViseGrips and probably magnets and other ****. Also made a mount for my hammer on the inside left of the bench.

I wanted to mimic the front inset on the bench in the design for the clamps. I made the racks out of 1 1/4 14GA tubing. Went with 1 1/4 as when 45'd it sits flush with a 2in tube.

These KantTwis clamps are pretty slick. Clamping a 45 cut piece of piece of square is always a handy feature to have. Also a bit easier to use one handed than some others.

This is the top vise grip rack on the right side. Its inset inwards about 7 inches so when I put the 11SP's on the rack the ends wont sit past the end of the table. Yes, I could of put them vertically, but that would not let me dual a dual rack of clamps and would waste space, not to mention would be pretty awkward to take/replace them.

This is the Bessey rack on the left side. This one is outset around 3 inches to make it easier to grab clamps under the lip of the table. I also capped the ends of the tube and ground them flush.

and last but not least, GOT THE TOP ON! The whole process was actually pretty easy. I was pleased. Also, the top is pretty damn flat so I am happy with that. I'll be picking up some Muriatic Acid tomorrow and giving that a go on the top. I'll see how it turns out.

Small things left to do
- Mount the 4 gang power box and find a way to deal with the 15ft of 12/3 cord.
- Make some sort of grinder rack on the back.
- Cut the expanded steel for the floor.
- Find a way to hang my 4 Bessy Corner Clamps

and any other small stuff I think of.

 

[ilovevocs]

For power cord management I actually mounted a small cord reel to my table and swapped the plug to a male on the "pull out" end and hard wired the opposing to the box. It was a simple way to store the cord.

I don't have the bench anymore but it worked well in my old shop. New shop is too small for anything to be mobile.


Sent from my iPhone using Tapatalk

 

[wrenchMONKEY_]

Got to use the table today! Had to swap out some teeth on a excavator bucket. Man oh man was it nice working at that height and having a solid table to work on!

After that I spent a bit of time on the top. The muriatic acid did a good job but I guess I was not as blown as away as I thought I'd be. So, spent about 30 minutes with a wire cup brush then followed by a few strip pads. I did a rainbow pattern from corner to corner on all 4 sides of the table. Got it pretty cleaned up, I am happy now.

Finished up the other clamp rack for the KantTwis/Magnets. I TIG'd this one out on the table and I am already in love.

Took my vice off my work bench. I need to find at piece of 10x10 plate that I want to make the base out of then then I'll plasma that out and then weld it up. Also thinking of getting a mini 3" bench grinder to put in one of them for grinding tungsten. Seems like it would be handy.

Need to sort out where I want to mount my outlets. I am thinking inside right, but that area is kinda cluttered already. I am thinking that maybe perhaps doing another box and putting on the middle of each short side would be the best. The "front" of the table is a bit busy.

To do -
-Cut expanded steel for lower shelves
-Grinder/Angle Clamp mount. Thinking something along the back side of the bench.
-Outlet install
-New chair/stool

 

[MarkG]

It's nice to see one of these 'over-built' welding tables we all love, with something heavy on it! Good job.

 

[wrenchMONKEY_]

Got the outlets wired up and installed a hook for the cable.

Finished up the vise mount.

Started cutting the expanded metal for the floors. I like the asthetics of insetting it about 1/2in, but man oh man is it a PITA to get a perfect cut. OH well, only three more to go.

 

[wrenchMONKEY_]

It's nice to see one of these 'over-built' welding tables we all love, with something heavy on it! Good job.

Thanks for the kind words!

 

[wrenchMONKEY_]

Got the shelving in. Works well for holding my welding blankets and corner clamps, I'll probably throw my TIG rod and stick stuff down there until I get some better storage on my Snycrowave200.

Now I just need to sort out where/how I am going to mount my grinders and thats pretty much it. Probably going to do something on the back end for perm storage and I'll probably make a trailer hitch item for racking my grinders when i am working.

Very happy at the overall product.

Still have not attached the top in any way, but its not going anywhere. Still undecided if and when I am going to drill a grid pattern on the top or if I'll just leave it as is.

 

[MarkG]

I'd probably at least put a few heavy spot welds underneath, just to keep it from ever sliding around when it's being pushed around. I just like the idea of it being fixed in place. Eliminate any potential or rocking or teetering, etc. (or clattering as it's rolled around) As a welder, it's a little embarrassing to have things be loose!

 

[mike13u]

Nice job

 

[wrenchMONKEY_]

Few points I thought I'd add -

I was going to go all out for a grinder rack, but I ended up going with some 2in angle. KISS

I wish I went with locking casters. I thought the table would be alot more stationary that it has been. At 1000 lbs on a uneven floor, it can get away from you. It rolls really well and smooth, but still, locking casters would of been the way to go.

Paint. Its hard to know what your gonna do, but when you think your done, your never done. Still, getting the top off, painting the frame complete is gonna be a PITA.

Electrical. I'll probably get some wire and run another 4 outlet box to the other side of the table. I've found my self wanting power on all sides of the table.

All that being said. Love it!

 

[JTH]

Very nice work ending with a great table!

 

[Disturbed Sledneck]

Very nice table! Overbuilt but I wouldn't have it any other way.

 

[bimmer1980]

Nice looking table and very functional. I like how the lower shelf is inset.

 

[NUTTSGT]

Beautiful and well thought out table.

After selling the other sections of top steel, how much are you into the original $440 for ?

 

[Thumper68]

Don't know how I missed this the first time around but great work. That table should serve you well.

 

[wrenchMONKEY_]

Appreciate all the comments. The table has been great. I love it. Makes things so much easier. Just need to run power on the back side and Ill be done.

Everything all said and done after selling the steel I ended up with some beer money in my pocket.

Latest project. Rock sliders for my truck. Also traded my Miller 211 and 375 Plasma for a Miller 252 with Spoolgun and a Hypertherm Power Max45. Good trade.

 

[NUTTSGT]

Sounds like you are doing alright in the shop !

One question though, all the cutting and welding, how do you avoid catching that chair on fire ?

 

[NoPressure]

Very nice. I really like the recessed expanded metal.

 

[GLTHFJ60]

Love the lower shelf design.

 

[kazlx]

Nice job. I like the Heuer vise. I did the same thing for my first table and scored a table off CL for $100. Definitely the way to go.

 

[Rory Bellows]

Few points I thought I'd add -

I was going to go all out for a grinder rack, but I ended up going with some 2in angle. KISS

I wish I went with locking casters. I thought the table would be alot more stationary that it has been. At 1000 lbs on a uneven floor, it can get away from you. It rolls really well and smooth, but still, locking casters would of been the way to go.

Paint. Its hard to know what your gonna do, but when you think your done, your never done. Still, getting the top off, painting the frame complete is gonna be a PITA.

Electrical. I'll probably get some wire and run another 4 outlet box to the other side of the table. I've found my self wanting power on all sides of the table.

All that being said. Love it!

Get a floor lock. You could probably get away with one but two would be rock solid.

 

[Jo Diesel]

Any thoughts on some holes out in the center for clamping?

I am trying to figure a good way to mount a LED light on the next one I build. Maybe something like this on an arm.

 

[Farmall450]

Great score on the plate brother! Was that a craigslist find? Good looking work on the table too!

You can say that again, hell of a deal! & Hell of a setup, tho I'd almost have left it as one sheet