Project 2 from zedron. Category: Welding Cart

So I was at my friends shop messing around with my 200DX and he started complaining about how one of the guys who work for him forgot to turn on the water cooler and burnt up a new torch that was replaced only about 2 weeks ago. Prior to this he was complaining about how he needed a new cart for his inverter thermal arc welder too. So I said why don't you make the new cart but add a breaker to the cart that turns on the welder and cooler with a single switch. He said he doesn't have time and would love to get around to do that but time time time. So, to get some seat time in with my new welder and just general practice I offered to make one for him using his materials. The look on his face seems like he just won the lottery, lol. Its teh least I can do since I use all of his material/equipment when I need something made or fixed.

So here we go... will be finishing either later today or tomorrow.

Material used so far: 1/8 rectangular AL pipe, 1/8 AL plate, Misc electrical stuff, SS Rivets, SS Screws
Filler Rod: 3/32 5356
Tungsten: 3/32 2% thoriated
Cup: #5
Settings: 150A, 220Hz, 30-40% Balance, Was messing around between foot pedal and also torch switch, No pre-flow, 4 sec post flow, 18 CFH Argon flow, no pulse

Pic 1: Completed frame. The bottom part is for the water cooler, the next part is for the welder, and the top will have a hinged top with a tray set in to hold consumables, the top will also be able to act as a little welding top. Not sure if I want to put caps on the end of the pipe or not...
Attachment 8731
Pic 2: This is the shelf for the welder. I just drilled the holes and will just use rivets to hold it in place.
Attachment 8732
Pic 3: Of course when you design stuff on the fly you usually come into problems. This is where I had to cut the top front support and move it back. When I put the welder in, the front brace wouldn't allow the front lid of the welder to open fully....ugh. So here it is being cut off to be relocated.
Attachment 8733
Pic 4: Front brace cut off and welding shelf riveted in.
Attachment 8734
Pic 5: New brace location. Since the brace is getting moved back, the tray I will insert inside will be smaller and so will the table work top, o well.
Attachment 8735
Pic 6: Quick weld shot
Attachment 8736
Pic 7: Another weld shot. I didn't prep the metal at all so all the oil and grease is still on there. Its not my welding cart...lol.
Attachment 8737
Pic 8: Breaker box clamped down and drilled ready for set screws.
Attachment 8738
Pic 9: A little green picture love. Nothing like using the Everlast machine to make a cart for a thermal.
Attachment 8739
Pic 10: Set screws in. Dont mind my not safety foot attire...
Attachment 8740

Pic 11: Went out to grab lunch and stopped at Northern Tool for some wheels. I went rummaging through the scrap he had and was able to find one piece that fit the wheel perfectly for the mounting plate. Just need to do a little trimming and we will be good to go.
Attachment 8741
Pic 12: Other two wheels was not so lucky. Will have to do a little more cutting on these.
Attachment 8742

So far so good. I think the design so far is good and I might copy it for when I do mine. I will modify it a little because I will need to add a part for a bottle and I will not be using a water cooler, so I can make that section some more storage with drawers hopefully. Next step is to put wheel plates on, wheels, make tray, make lid with hinges, wire up plugs, add some hooks for cables, and maybe make some type of holder for foot pedal.

Pic 13: Preliminary wiring done
Attachment 8801
Pic 14: Trays and top are in
Attachment 8802
Pic 15: Work top complete.
Attachment 8803

All that is left is a holder for foot pedal, add wheels, snug everything in, and then make some cord holders.

Nice work. Are you using the breaker as the switch? I haven't seen the done before but I like it.

Sent from my PC36100 using Tapatalk 2

Quote:

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Originally Posted by greygizmo

Nice work. Are you using the breaker as the switch? I haven't seen the done before but I like it.

Sent from my PC36100 using Tapatalk 2

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Sure am. The breaker will act as the switch while the cooler and welder will remain in the ON position on their own switches. My friend has had a few torches burned up because the people who work for him have forgot to turn on the cooler.

Nice aluminum cart. When I get the 255 EXT I will make a cart that I never built for the 250 EXT. I may need to look into an aluminum cart. How much did the material cost for the build?

Quote:

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Originally Posted by DVA

Nice aluminum cart. When I get the 255 EXT I will make a cart that I never built for the 250 EXT. I may need to look into an aluminum cart. How much did the material cost for the build?

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So far the wheels cost $60. As far as the AL rectangular tube goes I am not sure as it was already available in stock in the shop. I am curious though as I will be making my personal one out of AL as well. I will find out how much a stick of the rectangular tube costs and let you know.

Pic 16: Complete
Attachment 8985
Pic 17: Complete with trays having a purpose.
Attachment 8986

I was gonna make a little holder thing for the pedal but decided not to for the time being. I dont think I will ever make one for it as this machine always has a switch on it anyways.

Quote:

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Originally Posted by DVA

Nice aluminum cart. When I get the 255 EXT I will make a cart that I never built for the 250 EXT. I may need to look into an aluminum cart. How much did the material cost for the build?

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The retail price for a 25ish foot piece of that rectangular tube is roughly $50 or so.

I like the cover on the trays. Keeps all the crud from accumulating in them, yet easy to fish things out.

Nice job. I like the Circuit breaker Ideal. I invision the top being used as a mini welding table lol.

Thats an interesting design. I purchased aluminum to build 2 carts and the tubes is not what draws up the price. The expensive part is the aluminum sheets to make the shelfs/sides.

Did a little more work. Added a handle and started to make some gizmo to hold the welder down in place.
Attachment 9026

Bored on a Sunday so finished welder holding gizmo and painted with some leftover Black hammered rustoleum paint..... Not bad.
Attachment 9027
Attachment 9028