1×2 × 1/8" wall rectangular tube
Welding Cart Cut List and Cutting Plan
Every frame member, post, rail and arm for the cart, plus a plan that gets all of them out of six 10 ft sticks with about 4" to spare on each.
Frame
Letters match the frame plan. LP means long point: measure mitered pieces along their outside face, point to point.
| ID | Member | Qty | Ends | Length |
|---|---|---|---|---|
| A | Front rail. Outside corners mitered. | 1 | 45° both ends | 62" LP |
| B | Rear rail. Outside corners mitered. | 1 | 45° both ends | 62" LP |
| C | End rails. Outside corners mitered to A and B. | 2 | 45° both ends | 33" LP |
| D | Spine crossmember. Carries the bench's back edge and every spine post (C to E). | 1 | square | 45¾" |
| E | Bench-end member, the edge of the welder bay (A to B). | 1 | square | 31" |
| G | Divider between the cylinders and the plasma (D to B). | 1 | square | 12½" |
| H | Directly under the cylinder centers, also the front of the rear-left caster pocket (C to G). | 1 | square | 22½" |
| P | Caster pocket sides: 3 at 8", 4 at 7". | 7 | square | 52" total |
Every miter is a 45° cut across the 1" face, so it closes a corner in plan. Square-cut pieces butt against the inside face of the member they meet, out of sight.
Posts, rails and arms
| Part | Note | Qty | Ends | Length |
|---|---|---|---|---|
| Cylinder upright | Left end of the spine. Cap the top. | 1 | square | 41⅜" |
| Shared upright | Cylinders and both shelves. Stops under the upper shelf, which covers its top. | 1 | square | 41¼" |
| Shelf post | Stops under the upper shelf, which covers its top. | 1 | square | 41¼" |
| Lead post / end post | Welder end. They stop under the L top frame. | 2 | square | 39¼" |
| L top rail | Runs along the welder end on top of the lead and end posts. | 1 | 45° both ends | 33" LP |
| L front arm | From the top rail's front corner to the shelf post line. Cap the open end. | 1 | 45° outside, square at vent gap | 14¼" LP |
| L rear arm | Along the back edge, from the top rail's back corner to the shelf-post arm. | 1 | 45° both ends | 17¼" LP |
| Upper shelf arm, shelf post | Laps the shelf post's left side for its full 1" depth, then runs to the back edge. | 1 | 45° back, square front | 14½" LP |
| Upper shelf arm, shared upright | Laps the shared upright's right side for its full 1" depth. Cap the end. | 1 | square | 14½" |
| Lower shelf arms | Lap the shared upright and the shelf post, flush with the bench top, to the back edge. Cap the ends. | 2 | square | 14½" |
Adjust the posts to your bench
Post lengths assume a 29" bench with its casters off. If yours is different, add or subtract the difference on all five posts. The before-you-build checklist lists the other measurements to take.
Cutting plan: six 10 ft sticks
(M) marks a mitered piece. Leftovers allow 1/8" of kerf per cut plus about 1" of waste for each mitered end, so you can cut every miter from a fresh square end.
| Stick | Cuts | Used | Left |
|---|---|---|---|
| 1 | A 62 LP (M) · C 33 LP (M) · upper shelf arm 14½ LP (M) | 109½" | ~5⅛" |
| 2 | B 62 LP (M) · L front arm 14¼ LP (M) · lower shelf arm 14½ · P 7 ×3 | 111¾" | ~4½" |
| 3 | D 45¾ · L top rail 33 LP (M) · C 33 LP (M) | 111¾" | ~3⅞" |
| 4 | cylinder upright 41⅜ · end post 39¼ · upper shelf arm 14½ · G 12½ · P 8 | 115⅝" | ~3¾" |
| 5 | shelf post 41¼ · shared upright 41¼ · L rear arm 17¼ LP (M) · P 8 · P 7 | 114¾" | ~2⅝" |
| 6 | lead post 39¼ · E 31 · H 22½ · lower shelf arm 14½ · P 8 | 115¼" | ~4⅛" |
Every stick has about 4" spare. That's room for one bad cut on each, but not two.