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Thread: Yet another DIY welding cart...

  1. #1
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    Yet another DIY welding cart...

    Well, with the arrival of my new TIG machine:



    It became obvious I need another cart. I needed a TIG machine with some good punch to do some intake manifolds for my Vette and this mean-mamma-jamma carried a full 250 amps (AC) but still dials down to a trickle at 5 amps. 250a is enough to punch through the cast aluminum I plan to do and 5A is low enough to weld pop cans and razor blades together without turning them into a melted pule of goo. My skill level, however, is a different story....

    I was not relishing the thoughts of spending good money on another cheap cart when I thought to myself, why buy a cart when you can weld?

    So I sat down and did some thinking about my needs, some imagining, some drawing and some cyphering and came up with this:






    Certainly not done, but its a good start. That's all steel I had left over from other projects. I built it to hold the everlast, a Lincoln 180C and the cooler for the TIG. Of course, cables tools and filler rods as well.

    The very bottom space will hold the tank and rad for the TIG torch cooler. There will likely be a small storage space in front of it. Theres a big gap between the MIG shelf and the TIG shelf for a reason; there will be a full length drawer there split into compartments to hold my TIG stuff (collets, tungstens, cups, etc).

    The rest comes down to some brackets and holders for cables, torches, gas lines, etc. Im undecided on filler rod storage. Not sure if I want to put tubes on the outsides of the cart or through the shelves (like the one in the pic).

    Still to do;

    Bottle holders
    Shelf floors
    Drawers
    Tig cooler
    Front caster wheels
    Add a small grinder for grinding tungstens
    Paint
    And: dream up anything else I might want/need

  2. #2
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    Re: Yet another DIY welding cart...

    Made some decent progress today. Welded on the shelf floors, added vertical supports, front casters, cut some horse stall mats to fill the space in the shelves (rubber keeps things from sliding around, adds heft and keeps the metal from clanking/ringing), started building the tank retainers and built the drawer:







    Still have a long way to go, but making good progress.

    I originally wanted to leave the shelves open and have that "floating" look, but once it was together, there just seemed to be a touch too much flex in the assembly for my liking. I had no problem dropping my 200 lbs on a shelf and it not moving much, but I just couldn't get that "warm and fuzzy" without adding support to the front parts of the shelves. I think it still looks pretty good, even without the "cantilevered" shelves.

    The drawer came out OK, but it's about twice as deep as it needs to be. Probably could have put two drawers there instead of the one. I may make a hinged panel (or maybe a "lift out" one might be a better way to go) to create an upper and lower section in the drawer.

    Next is to build the cord storage hangers. The angle cuts need to be closed up on the supports and the bottle holder needs to be filled in and a clamp built to retain the bottles (the chain is only temporary). The drawer needs to have dividers built and installed to keep the assorted bric-a-brac organized. Still have to sort out some filler rod holders.

    I also need to figure out some sort of "handle" for moving it around the shop. I'm only a hobbyest in his two car garage, so everything has to go in/on the cart and it needs to be "moveable" with relative ease. As it sits, it still rolls around easily. We'll see how it goes once it's fully built and loaded up.

    Next up will be building the tig torch cooler, which will fit under the TIG machine. It's going to be fairly simple: an aluminum container, a submerged pump (from a tile saw) a radiator and a fan. Plan it to build it right into the cart itself which will, hopefully, leave enough space in front of it for some consumable storage (wire, etc).

    Probably have to start thinking about a color to paint the thing. Red jumps to mind, mostly because the Lincoln is red and I have a gallon can of Tremclad (IE: Rustoleum) red. Green Everlast will stick pretty good out though. I suppose black is always and option too....
    Last edited by gr8twhite; 12-01-2019 at 09:20 PM.

  3. #3
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    Re: Yet another DIY welding cart...

    More work:





    Those are holders for the TIG filler rods. Most guys go vertical with them, I went horizontal so I could put shorter used rods in the tubes and still be able to get them back out. I may change them to vertical mounted though. They take up quite a bit of space this way, which makes it harder to find a corner to store the cart in without the rod holders sticking out...

  4. #4
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    Re: Yet another DIY welding cart...

    Looks good I especially like the parts drawer.

    It looks like you accidentally built the two shelves an inch or two short, though, so you're forcing the machines to sit up on the lip. Maybe it was on purpose, but it looks accidental.

  5. #5
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    Re: Yet another DIY welding cart...

    On purpose. Although, i do wish Id made the lower shelf with the tig another inch or so. The tig fits, its just a teeny bit paat the front of the shelf....

  6. #6
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    Re: Yet another DIY welding cart...

    Quote Originally Posted by gr8twhite View Post

    Probably have to start thinking about a color to paint the thing. Red jumps to mind, mostly because the Lincoln is red and I have a gallon can of Tremclad (IE: Rustoleum) red. Green Everlast will stick pretty good out though. I suppose black is always and option too....
    Hit it all over with a flap disc to polish it smooth, and clear coat it, to retain the natural steel appearance but prevent it rusting.
    Then if you need to weld something else on it later to add what you have not thought of now, it will be easy to match and only needed where you did the addition.

  7. #7
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    Re: Yet another DIY welding cart...

    Crude. Safe and functional.It gets it done

  8. #8
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    Re: Yet another DIY welding cart...

    Coming along:




    I changed the rod holders to vertical because they just took up too much room in the garage in the horizontal postion. With a 2 car garage, space is at a premium, hence the two welders in one cart.

    I added a handle to the top to make it easier to move around. As the weight was going up, it was getting harder to roll it around. So, the handle was added and things got much easier. As a side bonus, I left the square tube ends open and it works great as a MIG torch holder. It a welcome addition as Im always looking for somewhere to put my hot torch. Ill be making a magnetic torch holder soon too.

    Ive never liked the look of the cables hanging loose. It just looks so....messy. So:



    Left over M/C front brake rotors that have been hanging around forever. So I tacked them on and they cover the cables nicely. But Im a little back and forth on whether I like the look of them or not. Maybe I need some kind of design insert to fill in the empty space in the center so they dont look like someone just stuck a couple okd brake rotors on there...

  9. #9
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    Re: Yet another DIY welding cart...

    Quote Originally Posted by Bonzoo View Post
    Crude...
    Seems a little unkind, especially considering Im not anywhere near done building it...
    Last edited by gr8twhite; 12-03-2019 at 07:58 PM.

  10. #10
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    Re: Yet another DIY welding cart...

    Quote Originally Posted by gr8twhite;8

    [url=https://servimg.com/view/19980774/602
    [/url]

    Left over M/C front brake rotors that have been hanging around forever. So I tacked them on and they cover the cables nicely. But I’m a little back and forth on whether I like the look of them or not. Maybe I need some kind of design insert to fill in the empty space in the center so they don’t look like someone just stuck a couple okd brake rotors on there...
    Maybe weld a 1/4" rod horizontal across the center of them and use it to hang grinders on by the wheel guard. No sense in adding weight to the cart if it doesn't serve a function, besides aesthetics.

  11. #11
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    Re: Yet another DIY welding cart...

    Quote Originally Posted by Bistineau View Post
    Maybe weld a 1/4" rod horizontal across the center of them and use it to hang grinders on by the wheel guard. No sense in adding weight to the cart if it doesn't serve a function, besides aesthetics.
    That's a pretty good idea. I'm always looking for a plase to put the grinder down when using it.

    I also thought I might make a receiver style mount in the center of one of them so I can mount a small grinder for doing tungsten when I need to....

  12. #12
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    Re: Yet another DIY welding cart...

    couple of old wrenches welded across rotors to hang grinders on
    either you LIKE BACON or you're WRONG!!!! "There are three kinds of men.The ones that learn by readin'.The few who learn by observation.The rest of them have to pee on the electric fence for themselves"-Will Rogers

  13. #13
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    Re: Yet another DIY welding cart...

    Quote Originally Posted by gr8twhite View Post
    That's a pretty good idea. I'm always looking for a place to put the grinder down when using it.....
    A piece of flat stock 1"x1/8" or so size could serve the same purpose. Maybe put a little bit of bend at each end, so it stands out away from the disc some to give a bit more room to hang the grinders on.
    Last edited by Bistineau; 12-04-2019 at 09:51 PM.

  14. #14
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    Re: Yet another DIY welding cart...

    not crude but functional. you did say you're capping those open miter cut tubes? nice custom work imo.
    i.u.o.e. # 15
    queens, ny and sunny fla

  15. #15
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    Re: Yet another DIY welding cart...

    Quote Originally Posted by Bistineau View Post
    A piece of flat stock 1"x1/8" or so size could serve the same purpose. Maybe put a little bit of bend at each end, so it stands out away from the disc some to give a bit more room to hang the grinders on.
    1/8 is too thick for some grinders. 12-14 gauge will pretty much work for all.

    Sometimes I do cutouts.



    :

  16. #16
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    Re: Yet another DIY welding cart...

    You cart Looks great, Congrats on the new purchases as well. I'd clear coat it with permalac or penetrol and keep the bare steel/work look. Hides the wear better than a solid paint job and is laughably easy to touch up. I happen to like the look as well.

    I've also hung the grinders from the handles in the same manner, to stack more in less space. It's slower though so I hang them from the wheel guard near the work, and from the handle for storage (99 problems but too few grinders aint one).

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