Page 1 of 3 123 LastLast
Results 1 to 25 of 59

Thread: Welding Cart

  1. #1
    Join Date
    Nov 2014
    Location
    North Readung, MA
    Posts
    93
    Post Thanks / Like

    Welding Cart

    So I started building my first welding cart. This one will hold, from bottom up, fume extractor, water cooler, Dynasty 200.
    Building the cart using 2" 1/8" thick hot rolled steel

    Any comments and critiques are welcome

    Here is the plan:
    Name:  IMG_1716.jpg
Views: 3165
Size:  38.0 KB


    On the flat deck surfaces, I knew that I wanted the corners to have the flat look for the welds, so i created a couple sample coupons with different joint designs from the The Procedure Handbook of Arc welding. The suggested joint design was a flat butt weld, but I didn't want to do a lot of grinding. I also had to decide if I wanted to weld using GMAW or GTAW. Here are some pictures of the the coupons and practice welds.

    These are beveled joints coupon.
    Name:  IMG_1717.jpg
Views: 3160
Size:  51.1 KBName:  IMG_1718.jpg
Views: 3149
Size:  45.1 KB

    The inside of the joint checking penetration
    Name:  IMG_1719.jpg
Views: 3142
Size:  30.9 KB

    The outside corner joint. I was apprehensive with the heat and will definitely will need to use more pedal on the actual cart.
    Name:  IMG_1720.jpg
Views: 3141
Size:  24.6 KB
    Miller Dynasty 200 DX
    Millermatic 211
    Lincoln X-Tractor 1GC
    Hypertherm Powermax 1000

  2. #2
    Join Date
    Nov 2014
    Location
    North Readung, MA
    Posts
    93
    Post Thanks / Like

    Re: Welding Cart

    To get started, I ran a couple MIG fillet coupons on 1/4" material
    Name:  IMG_1725.jpg
Views: 3116
Size:  36.7 KBName:  IMG_1726.jpg
Views: 3119
Size:  58.3 KB
    Not the best welds, but they gave me what turned out to be false confidence.

    So the next test coupon was to test my MIG skills for fillet and butt welds on 1/8" material. BTW, you'll notice I took a corner coupon that I had but welded with no bevel, cut it in half and MIG butt welded it again with no bevel.
    Name:  IMG_1727.jpg
Views: 3132
Size:  66.5 KB Name:  IMG_1730.jpg
Views: 3113
Size:  40.9 KB
    Well, the fillet welds seem acceptable. Butt welds, I will need to practice with my MIG a bit more, use a different process, or change the joint design.
    Miller Dynasty 200 DX
    Millermatic 211
    Lincoln X-Tractor 1GC
    Hypertherm Powermax 1000

  3. #3
    Join Date
    Mar 2005
    Location
    Under a Rock
    Posts
    5,832
    Post Thanks / Like

    Re: Welding Cart

    probably the first welding cart I ever saw with a fume extractor....

    fancy stuff...

    Looking forward to the end result.
    Miller 211
    Hypertherm PM 45
    1961 Lincoln Idealarc 250
    HTP 221


    True Wisdom only comes from Pain.

  4. #4
    Join Date
    Nov 2014
    Location
    North Readung, MA
    Posts
    93
    Post Thanks / Like

    Re: Welding Cart

    After the debacle with the MIG butt welds, I needed to end the day on a high note so I laid down 3 TIG edge welds.
    Name:  IMG_1722.jpg
Views: 3102
Size:  48.6 KBName:  IMG_1723.jpg
Views: 3094
Size:  27.5 KB
    Name:  IMG_1721.jpg
Views: 3103
Size:  51.4 KB
    Last edited by jay gill; 10-03-2016 at 09:05 PM.
    Miller Dynasty 200 DX
    Millermatic 211
    Lincoln X-Tractor 1GC
    Hypertherm Powermax 1000

  5. #5
    Join Date
    Nov 2014
    Location
    North Readung, MA
    Posts
    93
    Post Thanks / Like

    Re: Welding Cart

    So I decided that the corner welds would be beveled joints on the flats, and I would flatted the outside corner before TIG welding them.
    Name:  IMG_1724.jpg
Views: 3089
Size:  27.8 KB

    Here are the result of the actual welds. It will be a couple posts because if the 5 picture limit per post
    Name:  IMG_1735.jpg
Views: 3096
Size:  33.7 KBName:  IMG_1736.jpg
Views: 3087
Size:  27.7 KB
    Name:  IMG_1737.jpg
Views: 3085
Size:  34.8 KBName:  IMG_1740.jpg
Views: 3083
Size:  58.9 KB
    As you can see, the first couple left some room for improvement. One I didn't add enough filler, I tried to add more after the fact. I feel like the picture is worse than it is in person, but that is no excuse, I should have done at least one practice coupon on the night before i did the real thing. I was also forcing myself to feed the filler with my fingers as opposed to choking up on the filler rod and dipping down to my fingertips.
    Last edited by jay gill; 10-03-2016 at 09:04 PM.
    Miller Dynasty 200 DX
    Millermatic 211
    Lincoln X-Tractor 1GC
    Hypertherm Powermax 1000

  6. #6
    Join Date
    Nov 2014
    Location
    North Readung, MA
    Posts
    93
    Post Thanks / Like

    Re: Welding Cart

    And here are the rest of the corner flats.
    Name:  IMG_1738.jpg
Views: 3074
Size:  42.7 KBName:  IMG_1739.jpg
Views: 3075
Size:  58.9 KB
    Name:  IMG_1741.jpg
Views: 3075
Size:  44.7 KBName:  IMG_1742.jpg
Views: 3073
Size:  42.7 KB
    Miller Dynasty 200 DX
    Millermatic 211
    Lincoln X-Tractor 1GC
    Hypertherm Powermax 1000

  7. #7
    Join Date
    Nov 2014
    Location
    North Readung, MA
    Posts
    93
    Post Thanks / Like

    Re: Welding Cart

    And finally the outside corners. Feeding the filler is causing me to go a bit slow and causing a bit too much heat to build up by the time i get to the end, and I'm not backing off the pedal enough. I'm not entirely unhappy, but want to do better or the remaining 7 outside corner joints left in the cart.
    Attachment 1519551Attachment 1519561
    Attachment 1519571Attachment 1519581

    And, a little out of order, but here is one with the rear axle through the mounting holes.
    Attachment 1519591

    That is all I have finished so far. Will post updates as I make more progress.
    Miller Dynasty 200 DX
    Millermatic 211
    Lincoln X-Tractor 1GC
    Hypertherm Powermax 1000

  8. #8
    Join Date
    Nov 2014
    Location
    North Readung, MA
    Posts
    93
    Post Thanks / Like

    Re: Welding Cart

    Quote Originally Posted by jay gill View Post
    And finally the outside corners. Feeding the filler is causing me to go a bit slow and causing a bit too much heat to build up by the time i get to the end, and I'm not backing off the pedal enough. I'm not entirely unhappy, but want to do better or the remaining 7 outside corner joints left in the cart.
    Name:  IMG_1745.jpg
Views: 2936
Size:  36.2 KBName:  IMG_1746.jpg
Views: 2946
Size:  46.7 KB
    Name:  IMG_1747.jpg
Views: 2927
Size:  32.5 KBName:  IMG_1748.jpg
Views: 2919
Size:  32.9 KB

    And, a little out of order, but here is one with the rear axle through the mounting holes.
    Name:  IMG_1743.jpg
Views: 2918
Size:  45.7 KB

    That is all I have finished so far. Will post updates as I make more progress.
    Fixing the missing picture
    Miller Dynasty 200 DX
    Millermatic 211
    Lincoln X-Tractor 1GC
    Hypertherm Powermax 1000

  9. #9
    Join Date
    Jan 2013
    Posts
    30
    Post Thanks / Like

    Re: Welding Cart

    Name:  welding cart.jpg
Views: 2756
Size:  55.5 KBName:  welding cart 2.jpg
Views: 2760
Size:  50.2 KBName:  welding cart 3.jpg
Views: 2751
Size:  51.3 KB
    Looks like mine, I put a couple drawers and a middle section to hold 6 tubes of tig rod.

  10. #10
    Join Date
    Nov 2014
    Location
    PDX PNW
    Posts
    9,646
    Post Thanks / Like

    Re: Welding Cart

    Nice looking cart! Is that the dynasty on top or some kind of plasma cutter?

  11. #11
    Join Date
    Jun 2016
    Location
    Back to the jungle
    Posts
    4,038
    Post Thanks / Like

    Re: Welding Cart

    Make a stool. Siddown. Scribe lines on either side of your cut. Get comfortable and keep it between the lines.It looks like you're welding one handed standing on one foot.In a wind storm.Support your arms.Relax.The last few are looking a lot better tho. Weld on.

  12. #12
    Join Date
    Oct 2006
    Location
    Illinois
    Posts
    9,561
    Post Thanks / Like

    Re: Welding Cart

    Looks really nice. Maybe consider moving the bottom 211 to the center position. If you weld mostly on the bench it would provide a straighter cable with less bend for wire movement and gain a little extra length.

  13. #13
    Join Date
    Nov 2014
    Location
    North Readung, MA
    Posts
    93
    Post Thanks / Like

    Re: Welding Cart

    Jesse nice cart. did you make or acquire the drawers?
    Miller Dynasty 200 DX
    Millermatic 211
    Lincoln X-Tractor 1GC
    Hypertherm Powermax 1000

  14. #14
    Join Date
    Nov 2014
    Location
    North Readung, MA
    Posts
    93
    Post Thanks / Like

    Re: Welding Cart

    I made some more progress this week getting the upright welded on.
    Name:  IMG_1751.jpg
Views: 2577
Size:  50.3 KB

    Joint configuration was to space 1/16 of an inch using filler rod as the space. Rod was removed after tack welds were made and everything was checked for square.
    Mig welded. Didn't note settings, were the same as used to lay down the fillet in the the test welds above.

    I'm pretty happy with how these two came out
    Name:  IMG_1752.jpg
Views: 2563
Size:  40.9 KB

    Travel speed was a little slow on the fillet here
    Name:  IMG_1753.jpg
Views: 2569
Size:  40.4 KB

    I don't know why but I twitched in the middle of this fillet and went a bit fast.
    Name:  IMG_1754.jpg
Views: 2575
Size:  38.8 KB

    Overall I was happy with the side butt welds all around. The frame was rotated and positioned so they were all done in the flat position.
    This last one, i decided to push instead of pull and ended up with a bit of cold roll on the right end. Still deciding if I want to grind it out and re-weld
    Name:  IMG_1755.jpg
Views: 2565
Size:  34.9 KB
    Miller Dynasty 200 DX
    Millermatic 211
    Lincoln X-Tractor 1GC
    Hypertherm Powermax 1000

  15. #15
    Join Date
    Nov 2014
    Location
    North Readung, MA
    Posts
    93
    Post Thanks / Like

    Re: Welding Cart

    Last session was welding the top corners. Back to TIG.
    For the beveled flat joints i switched to 3/32 filler rod from 1/16.

    This first joint, I feel I added too much filler going over the tack.
    Name:  IMG_1756.jpg
Views: 2562
Size:  36.0 KB

    Took this picture after hitting it with the bristle disc. I slowed down and got a little hot i2/3 of the way across.
    Name:  IMG_1760.jpg
Views: 2562
Size:  35.1 KB

    This next one, I stopped and restarted in the middle
    Name:  IMG_1762.jpg
Views: 2569
Size:  63.2 KB

    This last one I was satisfied with.
    Name:  IMG_1763.jpg
Views: 2571
Size:  56.9 KB
    Miller Dynasty 200 DX
    Millermatic 211
    Lincoln X-Tractor 1GC
    Hypertherm Powermax 1000

  16. #16
    Join Date
    Nov 2014
    Location
    North Readung, MA
    Posts
    93
    Post Thanks / Like

    Re: Welding Cart

    Lastly the outside corners. I did have to stand for these, I was able to angle the frame and rest my right elbot on the frame for my torch hand and used a work support to rest my left elbow on for my filler hand.
    Name:  IMG_1767.jpg
Views: 2555
Size:  63.4 KB

    And for the welds themselves. They turned out decent I would say. A little too much pedal on the last 1/3 of the right picture flattened it out a little bit.
    Name:  IMG_1764.jpg
Views: 2549
Size:  37.9 KBName:  IMG_1766.jpg
Views: 2549
Size:  31.5 KB
    Miller Dynasty 200 DX
    Millermatic 211
    Lincoln X-Tractor 1GC
    Hypertherm Powermax 1000

  17. #17
    Join Date
    Nov 2014
    Location
    North Readung, MA
    Posts
    93
    Post Thanks / Like

    Re: Welding Cart

    Quote Originally Posted by Bonzoo View Post
    Make a stool. Siddown. Scribe lines on either side of your cut. Get comfortable and keep it between the lines.It looks like you're welding one handed standing on one foot.In a wind storm.Support your arms.Relax.The last few are looking a lot better tho. Weld on.
    Ergh, here is where i embarrassingly admit I was seated on a stool for all the welds that I had posted by the time you commented. I will say that my filler feed is still very shaky. I am trying to force myself to feed with my fingers and not move my hand as opposed to choking up on the rod and just dipping the rod until I get to my finger tips. If anything, because of this, I feel like I'm traveling too slow at times. I do agree that I do need to get better. Thanks for the feedback.
    Miller Dynasty 200 DX
    Millermatic 211
    Lincoln X-Tractor 1GC
    Hypertherm Powermax 1000

  18. #18
    Join Date
    Jan 2013
    Posts
    30
    Post Thanks / Like

    Re: Welding Cart

    Drawers came out of an old Lista toolbox at work. Top is a 625 plasma, diversion 180 in middle with enough room for dynasty 280 with cooler. mig is on bottom because I 90% weld with the tig. All machines are grounded to the cart, and I just have 1 long ground coming off the cart. I can take the machines off and use elsewhere if I need to though.

  19. #19
    Join Date
    Nov 2014
    Location
    North Readung, MA
    Posts
    93
    Post Thanks / Like

    Re: Welding Cart

    Took a little detour to setup my air system with dryers and reels so I will have clean dry air for the plasma cutter.
    Name:  IMG_1774.jpg
Views: 2158
Size:  51.6 KBName:  IMG_1778.jpg
Views: 2153
Size:  57.4 KBName:  IMG_1779.jpg
Views: 2154
Size:  32.0 KB
    Miller Dynasty 200 DX
    Millermatic 211
    Lincoln X-Tractor 1GC
    Hypertherm Powermax 1000

  20. #20
    Join Date
    Nov 2014
    Location
    North Readung, MA
    Posts
    93
    Post Thanks / Like

    Re: Welding Cart

    Got back to welding lat night. Got the second shelf welded on. Joint configuration included 1/16" space to allow for full penetration.
    I also switched from push to pull for the fillets (My welding class taught us to always push):
    This first one didn't start so great but as its welded on all 4 sides:
    Name:  IMG_1797.jpg
Views: 2150
Size:  45.9 KB

    The remaining 3 were fine:
    Name:  IMG_1784.jpg
Views: 2143
Size:  34.0 KB
    Name:  IMG_1785.jpg
Views: 2142
Size:  49.9 KB
    Name:  IMG_1798.jpg
Views: 2147
Size:  45.1 KB
    Miller Dynasty 200 DX
    Millermatic 211
    Lincoln X-Tractor 1GC
    Hypertherm Powermax 1000

  21. #21
    Join Date
    Nov 2014
    Location
    North Readung, MA
    Posts
    93
    Post Thanks / Like

    Re: Welding Cart

    The side welds are serviceable. I did blow a couple holes pulling so I changed motion to pushing with the cursive 'e'. Cart was rotated so the welds we performed in the flat position. I unfortunately didn't take the pictures in the order I welded nor can i remember from looking at them.
    You'll notice the restarts, those were the 1st two. Also ended the weld in the first picture a little quick and have a less than ideal crater:

    Name:  IMG_1786.jpg
Views: 2146
Size:  23.9 KB
    Name:  IMG_1787.jpg
Views: 2153
Size:  31.7 KB
    Name:  IMG_1788.jpg
Views: 2147
Size:  31.3 KB
    Name:  IMG_1789.jpg
Views: 2133
Size:  31.1 KB
    Miller Dynasty 200 DX
    Millermatic 211
    Lincoln X-Tractor 1GC
    Hypertherm Powermax 1000

  22. #22
    Join Date
    Nov 2014
    Location
    North Readung, MA
    Posts
    93
    Post Thanks / Like

    Re: Welding Cart

    And the corners. I did change plans a little and decided i'm going to weld and grind flat. First 2, on bottom were MIG and ground before i took a picture:
    Name:  IMG_1782.jpg
Views: 2128
Size:  26.8 KB
    Name:  IMG_1783.jpg
Views: 2136
Size:  30.0 KB

    For the second 2 weld, on the top side, I went back to TIG. First was a little concave, so I did a second pass:
    Name:  IMG_1791.jpg
Views: 2127
Size:  28.8 KB
    Name:  IMG_1793.jpg
Views: 2121
Size:  28.8 KB
    Miller Dynasty 200 DX
    Millermatic 211
    Lincoln X-Tractor 1GC
    Hypertherm Powermax 1000

  23. #23
    Join Date
    Nov 2014
    Location
    North Readung, MA
    Posts
    93
    Post Thanks / Like

    Re: Welding Cart

    And the top side corners after grinding:
    Name:  IMG_1794.jpg
Views: 2123
Size:  46.7 KB
    Apparently only took a picture of one.

    And the outside corners. I was too lazy to re-position the cart to get them to the flat position, so the were done vertically. The first picture come out good. The second I wandered with the filler a little and left some of the flat grind showing, so I went over with a second pass:
    Name:  IMG_1795.jpg
Views: 2124
Size:  43.4 KB
    Name:  IMG_1796.jpg
Views: 2130
Size:  40.4 KB
    Miller Dynasty 200 DX
    Millermatic 211
    Lincoln X-Tractor 1GC
    Hypertherm Powermax 1000

  24. #24
    Join Date
    Nov 2014
    Location
    North Readung, MA
    Posts
    93
    Post Thanks / Like

    Re: Welding Cart

    So I've been making some slow progress here and there, and haven't had much time to post. For welding the rest of the shelf attachments and front wheel mount plates I switched over to stick. 3/32 7018 Excalibur 90A.

    First up the wheel mount plates:
    Name:  IMG_1882.jpg
Views: 1871
Size:  51.1 KB
    Name:  IMG_1883.jpg
Views: 1867
Size:  52.0 KB
    Name:  IMG_1885.jpg
Views: 1859
Size:  57.0 KB
    Name:  IMG_1886.jpg
Views: 1860
Size:  56.9 KB
    Miller Dynasty 200 DX
    Millermatic 211
    Lincoln X-Tractor 1GC
    Hypertherm Powermax 1000

  25. #25
    Join Date
    Nov 2014
    Location
    North Readung, MA
    Posts
    93
    Post Thanks / Like

    Re: Welding Cart

    And a couple welded as the cart sat in overhead position to keep up the practice. Not as pretty as the other side.

    Name:  IMG_1887.jpg
Views: 1864
Size:  50.0 KB
    Name:  IMG_1888.jpg
Views: 1871
Size:  59.3 KB
    Miller Dynasty 200 DX
    Millermatic 211
    Lincoln X-Tractor 1GC
    Hypertherm Powermax 1000

Tags for this Thread

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •  
Page generated in 1,610,865,709.84755 seconds with 14 queries