How to Build the Welding Cart, Step by Step

Build order

1. 1

   Cut the tube

   Stand every tube on edge, 2" vertical. Cut the mitered pieces first, measuring long point, and test-fit each corner against a square before cutting its mate. Then cut the square pieces and deburr.

2. 2

   Make the caster mount plates

   Each of the four plates is two 7 × 7 squares of 11 ga stitched together, drilled on the caster pattern (2⅝ × 3⅜, centered; mark it from one of your casters first) and countersunk from the top for 3/8" flat heads.

3. 3

   Tack the perimeter

   Tack A, B and both Cs on a flat surface and square the frame until the diagonals match within 1/16".

4. 4

   Tack the interior

   Tack E, D, G, H and the P pocket sides. Check square again, then weld everything out with flush tops.

5. 5

   Weld in the mount plates

   Weld the plates into the four pockets, flush with the top and welded all around. Bolt on each caster and spin it a full turn to check clearance, then tack each bolt head in its countersink.

6. 6

   Weld in the bench corner pads

   Weld the three pads flush with the top, along the two members at each corner: A/E, C/D and D/E.

7. 7

   Drill the deck plates

   Put 3/8" plug-weld holes every 6–8" over the members and pocket plates underneath, plus an extra hole directly under each post location.

8. 8

   Weld the deck on

   Weld both plates flush with the edges. The rear plate's front edge runs along D. Butt weld the seam over E, stitch the edges with 1½" welds every 4–6", then plug weld the holes.

9. 9

   Set the bench

   Set the bench on its corner pads, tight against D. Check each caster plate lands on its pad and enlarge a pad if one doesn't. Mark the caster holes, drill, and bolt down with nuts underneath.

10. 10

    Stand the posts

    Weld each post all around over its plug-welded spot, get it plumb, then weld a 3 × 6 gusset to the post and the deck: on the back of the spine posts and on the inside face of the welder-end posts.

11. 11

    Add the accessories

    Finish with the parts that hang off the posts.

    • End posts, side rail and end hooks
    • Shelf arms and both shelves
    • TIG rod-tube rails
    • Chain eyes on the back of the cylinder uprights

Using the cart safely

• The front and rear casters are 24" apart. With tall bottles aboard, lock the casters while you work, and push from the bench end.
• Keep the 3⅜" gap between the bench and the welder open for ventilation. Don't store anything there.
• Chain both cylinders at both heights every time you load one.