Yet another welding cart project!

This is my first fabrication project with my Everlast PowerPro 256. I needed a welding cart that would hold my welder, tank, water cooler, air dryer, and accessories. I'm pretty happy with the way it turned out. The top is not intended to be a welding table, but rather open work space for clamps and stuff. I have another rolling steel welding table for actual welding.

I started with some heavy aluminum C channel I had laying around for the base frame. Then added 1.25x1.25x.120 6061 aluminum tube for the upper framework. I cut it with my band saw, then milled the ends so they were perfectly square before fitting up and welding. I used .125 aluminum diamond plate for the shelves. The wheels/tires are Harbor Freight specials. It rolls real easy and smooth over my cracked garage floor.

The shelves were placed specifically to fit my equipment, and are not the same height. There is enough space next to my PowerPro 256 to put a nice little Mig welder someday! The 110v quad box outlet is placed low so the short cord on my air dryer would reach. There is 1 1/2" of breathing space between the air dryer and water cooler so they can circulate air easily, but they draw primarily through the ends and not the sides. The cable hooks on the sides are door bolt hooks (the kind you slide a 2x4 through to secure a door).

If it looks like it leans back toward the tank a little bit, it's because it does. The front wheels are just a little too tall. It's not enough to cause any problems, and maybe someday I'll find some wheels that are 1/2" shorter, but for now it's fine.

Attachment 10162Attachment 10163Attachment 10164Attachment 10165Attachment 10166Attachment 10167Attachment 10168Attachment 10169Attachment 10170Attachment 10171

Nice cart. Do those small castors work well on your floor? There's probably a fair bit of weight over them so I'm curious how well they are working for you.

Quote:

---

Originally Posted by Mr120

Nice cart. Do those small castors work well on your floor? There's probably a fair bit of weight over them so I'm curious how well they are working for you.

---

Better than I expected. They were left over from another project, and I thought they might be too small as well. They roll nice and smooth even over my broken and cracked garage floor (pictures 4 and 6). They are bolt-on, so I can always change them if I ever want to.

Thanks!

Nice work HemiRod23 on you welding cart light weight and diamond plate to keep thing from sliding around.

Very nice cart. Milling the ends sure does make it easy to clamp things up square. Those really are some cracks! I guess I won't complain about my shop floor anymore.

PRIITY! SHINY!

Looks like everyone will be using the 3.99 HF wheels for their carts.

What brand is the bandsaw? How unsquare does it cut?

Quote:

---

Originally Posted by redbeard

PRIITY! SHINY!

Looks like everyone will be using the 3.99 HF wheels for their carts.

What brand is the bandsaw? How unsquare does it cut?

---

LOL, yep it was hard to pass up those $3.99 wheels! I think my band saw is an older Harbor Freight unit. I got it used from someone else, and it differs slightly from the ones they sell now. Properly adjusted, it's not too bad for accuracy, but the cuts were all slightly angled from top to bottom. Milling the ends just made them fit better. Thanks!

Quote:

---

Originally Posted by Rambozo

Very nice cart. Milling the ends sure does make it easy to clamp things up square. Those really are some cracks! I guess I won't complain about my shop floor anymore.

---

I would love to have my garage floor "mud jacked" and leveled, but I could probably buy a truckload of tools for what it would cost...

That's an awesome welding cart you built! I like everything about it, especially the diamond plate. The curved section that holds the Argon cylinder is a clever idea too! Its too bad you couldn't mount a bench grinder to the top with the welder and cooler right below. Of course, I guess you could add some curtains made from canvas or something to keep debris out of your machines. You could fit a bunch of ViseGrips and clamps, plus dollies and hold down weights on the top surface though, depending on how many you have. Those rear tires are perfect for a welding cart. I really wish I used bigger wheels/tires on mine! Those $3.99 HF casters are hard to beat! haha

Andy

Nice cart, always a good first project too if you do not have to get right to work. Aluminum is nice too. The rear tires go on sale all the time and HF for $3.99 as well. I have 2 left from the last trip. 2 on a dolly, and 2 on a large grill (soon to be smoker), bought 6 that time.

Those are some hefty cracks, hope they do not become a sink holes :D Mine are hairline, so like Rambozo, think I will stop complaining about mine as well after seeing yours.

Quote:

---

Originally Posted by youngnstudly

That's an awesome welding cart you built! I like everything about it, especially the diamond plate. The curved section that holds the Argon cylinder is a clever idea too! Its too bad you couldn't mount a bench grinder to the top with the welder and cooler right below. Of course, I guess you could add some curtains made from canvas or something to keep debris out of your machines.

---

Thank you Andy. I thought of that too. My benchtop drill press and grinder would fit up there nicely, but I don't want to get grit and metal filings in the equipment below. Side curtains would prevent air flow and would probably be in the way, so I just decided to leave them on the bench instead.

Quote:

---

Originally Posted by everlastsupport

Nice cart, always a good first project too if you do not have to get right to work. Aluminum is nice too. The rear tires go on sale all the time and HF for $3.99 as well. I have 2 left from the last trip. 2 on a dolly, and 2 on a large grill (soon to be smoker), bought 6 that time.

Those are some hefty cracks, hope they do not become a sink holes :D Mine are hairline, so like Rambozo, think I will stop complaining about mine as well after seeing yours.

---

I priced all the materials in both steel and aluminum, and aluminum was slightly cheaper. I was surprised, but since I can weld both, I went with aluminum to save some money and weight. The big HF tires roll nice on my Grand Canyon garage floor. Glad I went with them. They're also cheap and easy to replace if I ever need to. All thats left to do is mount the hose and regulator between the air dryer and welder for the plasma cutter, and cut the air lines for a perfect fit.

Quote:

---

Originally Posted by HemiRod23

LOL, yep it was hard to pass up those $3.99 wheels! I think my band saw is an older Harbor Freight unit. I got it used from someone else, and it differs slightly from the ones they sell now. Properly adjusted, it's not too bad for accuracy, but the cuts were all slightly angled from top to bottom. Milling the ends just made them fit better. Thanks!

---

The saw looks really close to the ones they sell now, just never saw it in blue. The one I just got has lots of slop and drops at about .030 off, so I need to return it and try for a good one.:(

Quote:

---

Originally Posted by everlastsupport

The rear tires go on sale all the time and HF for $3.99 as well. I have 2 left from the last trip. 2 on a dolly, and 2 on a large grill (soon to be smoker), bought 6 that time.

---

I was afraid I was the only one that bought a full bag of them when they were on sale. I wonder if they sell them that cheap just to boost their sales of slime. :D

Quote:

---

Originally Posted by redbeard

I was afraid I was the only one that bought a full bag of them when they were on sale. I wonder if they sell them that cheap just to boost their sales of slime. :D

---

I don't think so, since slime is name brand, they probably have bad margins on that, like rustoleum and 3M/bondo.. I mean, bondo at $20 and 25% off that, then walk in autozone or walmart and check the price...

I think it's to get you in the store and carry a bunch of heavy stuff around and give them more money on the way out, myself. Like the 20% and 25% coupons. :D Based on what happens to me.

Quote:

---

Originally Posted by everlastsupport

I think it's to get you in the store and carry a bunch of heavy stuff around and give them more money on the way out, myself. Like the 20% and 25% coupons. :D Based on what happens to me.

---

I think you've nailed it: "Just get them in the store" even if it means 20% off one item. They opened a store in my area so now it's 15 minutes away, and started flooding the circulars with coupons... and I started dropping by "to get tools for my son's starter tool kit"... then my daughter's starter tool kit... and I've got a younger son when the other tool kits are done... so I finally figured out I either need to quit going, or direct-deposit my paycheck at the HF.

Quote:

---

Originally Posted by everlastsupport

I don't think so, since slime is name brand, they probably have bad margins on that, like rustoleum and 3M/bondo.. I mean, bondo at $20 and 25% off that,

---

I never think to use the coupons on name brand stuff, of course with once-a-month visits, I usually wind up getting something more expensive than that anyway. I bet their real gravy money is in the multifunction oscilating tool blades and accessories, they are looking downright expensive for what they are. I guess the razor blade/inkjet business model must work pretty well - there is a 14.99 coupon for the tool for the 4th.

Quote:

---

Originally Posted by DaveO

I think you've nailed it: "Just get them in the store" even if it means 20% off one item. They opened a store in my area so now it's 15 minutes away, and started flooding the circulars with coupons... and I started dropping by "to get tools for my son's starter tool kit"... then my daughter's starter tool kit... and I've got a younger son when the other tool kits are done... so I finally figured out I either need to quit going, or direct-deposit my paycheck at the HF.

---

That was definitely the strategy a few years ago, I remember when the flashlights were absolutely free - no purchase necessary.