Having a flat,stable surface on which you can work is vital to the success of any welding project. Even better is a metal surface onto which you can clamp your welder’s grounding cable so that you’re not forced to clamp it to the actual project (an approach that, depending on the size or nature of your project, isn’t always practical).
This simple-to-build work cart provides a large welding surface, yet it doesn’t take up a lot of room in your shop. Because it’s on wheels, you can quickly move it out of the way when it’s not needed, and its storage shelf provides a handy place to keep welding gloves and supplies. Best of all, it’s built from metal stock that’s available at many home-improvement and hardware stores, which saves you the hassle of trying to find a local steel yard.
Build the structure
Start by cutting the 1-1/2 x 1-1/2 x 1/8-in. steel angle that forms the topframe pieces (A and B) and the 1-1/2- in.-sq. x 1/8-in. hollow tube that is the top center support (C) to size as indicated in the cutting list (p. 46), paying special attention to accurately cutting the miters. Lay out the four top-frame pieces on a flat surface, check for square and then weld them together (photo 1, p. 46). Mark the center of the long sides of the frame; then weld in place the top center support. Note that you’ll need to cut away one face of the center support before welding it to the underside of the top frame so that it will fit flush with the surface (photo 2).
Once you’ve completed the top framework, repeat the process to build the shelf framework. Pay close attention to the lengths of these components (D, E and F), as they are shorter than the top-frame pieces so that the shelf frame will fit inside the cart legs (see illustration).
Cut four 3/4-in. lengths of 3/8-in.-i.d. tube (G) to serve as mounting sleeves for the casters and weld them to the bottom inside corners of the four legs (H; photo 3); then weld the legs to the inside corners of the top frame, making sure that the legs are square and plumb with the framework (photo 4).
Once you’ve welded the legs in place, clamp the shelf framework inside the legs so that it’s positioned 5 in. from the leg bottoms. Check for square and then weld the shelf frame to the legs.
Create the top and shelf
Because most hardware and homeimprovement stores won’t stock 18- gauge sheet steel in a large enough size, you’ll need to build the top surface from two equal-size steel sections. (If you have access to a steel yard, you can purchase a single large sheet for the top.) Position the sheets (I) so that they are aligned with the top center support and use a permanent marker to trace the outline of the top frame onto the underside of the sheets. Use a jigsaw outfitted with a metal-cutting blade to cut the sheets along the traced line; then clamp them in place and weld them to the top frame and along the adjoining faces (photo 5).
Pay close attention to your welder’s voltage settings: You don’t want to burn through the thinner top material, yet you’ll need good weld penetration to securely attach the top sheets to the thicker frame pieces.
Use the same procedure to cut the two sheets of expanded metal mesh that will make up the shelf surface (J); then clamp them to the shelf frame and weld them in place. Because you’ll need to set the voltage high enough to get good weld penetration into the 1/8-in.-thick legs without melting through the mesh, start the weld puddle on the framework itself, and once you have enough molten material, draw the weld onto the ends of the mesh (photo 6).
Once all of the welds have cooled, use an angle grinder to smooth them and remove any rough edges. Flip the cart upside down and attach the four threaded casters into their sleeves. Wipe down the cart with mineral spirits to remove any oils or other residue; then paint the legs. Once the paint is dry, your cart is ready for service.
