Free DIY plans · 3D model · STEP file
The ultimate welding cart for big welders
A 62" × 33" rolling cart in 1×2 steel tube, designed around large multiprocess welders on water coolers, like the Everlast Lightning MTS 275-P. It also carries a 46" workbench, two cylinders, a plasma cutter and your TIG rods. Full drawings, cut list, build order and a STEP file for Fusion 360.
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Drag to orbit. Equipment is drawn see-through so you can see the frame.
- Footprint
- 62" L × 33" D
- Frame
- 1" × 2" × 1/8" wall rectangular tube, on edge
- Deck
- 11 ga sheet, 2 pieces, open under the bench
- Deck height
- About 6⅞" off the floor
What it carries
The cart was designed around a real kit, measured piece by piece, with a big welder and cooler at its center. The frame and deck stay inside 62" × 33". Only the cord hooks and coils hang off the welder end. See exactly where everything sits on the equipment layout.
46" Yukon workbench
Casters removed. The bench body is 46⅛" × 18³⁄₁₆" and sits on four corner pads in an open bay.
A big welder and its cooler
Sized for a 28" deep machine on a water cooler, like the Everlast Lightning MTS 275-P on a PowerCool W401. Controls face front, back flush to the cart.
Two gas cylinders
Up to 250 cu ft each, chained to the spine posts at about ⅓ and ⅔ of bottle height.
Plasma cutter
In an 18" × 10" bay behind the bench, with a shelf above it at bench-top height.
TIG rod storage
Five capped 40" PVC tubes in the cylinder-end corner, clamped to two rebar rails.
Leads and power cable
Coils hang on rebar hooks off the welder end, outside the 62" footprint.
Why build this one
01
Built from six sticks
Every frame member, post, rail and arm comes out of six 10 ft sticks of 1×2 × 1/8" tube, with about 4" spare on each for a bad cut.
02
Mitered where you can see it
Every visible corner is a 45° miter. Every hidden joint is a square butt. It looks finished without extra work.
03
Recessed casters
Boxed 1×2 pockets around doubled 11 ga plates drop the deck to about 6⅞" off the floor while keeping 1,000 lb casters.
04
A spine that does the work
One crossmember behind the bench carries the bench edge and every post. Gussets and the upper L shelf tie the posts together.
05
Room for the cooler to breathe
A 3⅜" vent gap between bench and welder, an open back, and an open right side keep air moving through the welder and cooler.
06
Everything has a home
Two 250s, a plasma cutter, five TIG rod tubes, two shelves, a helmet hook, and both coils, all on one 62" × 33" footprint.
What's in the plans
- Shop drawingsEquipment layout, frame plan and the mitered corner detail
- Cut list and cutting planEvery piece, and how to get them from six 10 ft sticks
- Materials and hardwareSheet parts, casters, bolts, rebar, caps and chains
- Build guideEleven steps from cutting the tube to hanging the hooks
- Interactive 3D modelOrbit, zoom, and switch layers on and off
- Will my welder fit?Fit checker with sizes for popular machines
- Printable PDF plansNine pages to take to the shop
- STEP file for Fusion 360About 70 named bodies in millimeters
Measure before you cut
Post lengths assume a 29" bench with its casters off. The welder and cooler stacked together need to be under about 39" above the deck to clear the upper shelf by a hand's width. If your kit differs, the before-you-build checklist shows what to adjust.
Want to change the design? Download the STEP file and open it in Fusion 360. Every body is named to match the cut list.