Project 2 from zedron. Category: Welding Cart

[zedron]

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...

Pic 2: This is the shelf for the welder. I just drilled the holes and will just use rivets to hold it in place.

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.

Pic 4: Front brace cut off and welding shelf riveted in.

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.

Pic 6: Quick weld shot

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.

Pic 8: Breaker box clamped down and drilled ready for set screws.

Pic 9: A little green picture love. Nothing like using the Everlast machine to make a cart for a thermal.

Pic 10: Set screws in. Dont mind my not safety foot attire...