Bill of materials
Welding Cart Materials and Hardware List
Beyond the six sticks of 1×2 tube in the cut list, the cart needs some 11 ga sheet, four casters, sixteen flat-head screws, a few lengths of 5/8" rebar, PVC for the TIG rods, and two chains.
Steel stock
| Item | Amount | Note |
|---|---|---|
| 1" × 2" × 1/8" wall rectangular tube | 6 sticks | 10 ft each. Frame, posts, rails and arms. |
| 11 ga sheet | 1 sheet | 4 × 10 covers the deck, pads, plates, shelves and gussets. |
| 5/8" rebar | about 10 ft | Rails, rim and hooks. Total of the pieces listed below plus waste. |
11 ga sheet parts
Sizes are in inches, width × depth.
| Part | Qty | Size and placement |
|---|---|---|
| Deck, rear row, 11 ga | 1 | 47¼ × 14½, from D's front face to the back edge |
| Deck, welder bay, 11 ga | 1 | 14¾ × 33. Meets the rear plate over the centerline of E. |
| Bench corner pads, 11 ga | 6 | 6 × 6, welded together in pairs at A/E, C/D and D/E |
| Caster mount plates, 11 ga | 8 | 7 × 7, welded together in pairs, countersunk for 3/8" flat heads |
| Middle shelf, 11 ga | 1 | 20¾ × 14½, top flush with the bench top, covering both arms to their outer edges |
| Post-base gussets, 11 ga | 5 | 3" × 6" right triangles, one at the base of every post |
| Upper L shelf, rear leg, 11 ga | 1 | 24¾ × 14½, at bench top + 12½", covering the tops of the shared upright and shelf post |
| Upper L shelf, welder leg, 11 ga | 1 | 14¼ × 33, over the welder. Welds to the rear leg at x = 47¾. |
Hardware, rebar and storage
| Item | Qty | Size and note |
|---|---|---|
| Casters, FOVERSWIVE 5" × 2" polyurethane | 4 | All four swivel with brake, 1,000 lb each, 6½" tall, 4 × 4½ top plate |
| 3/8-16 × 1" flat-head socket cap screws | 16 | For the casters, with flat washers and nylon-insert lock nuts |
| Bench bolts | to suit | Through the bench's own caster holes and the corner pads, nuts underneath |
| Tube end caps, 1×2 | 5 | On every visible open tube end |
| L shelf rim, 5/8" rebar | 1 | 31", along the free edge of the welder leg |
| Rod-tube top rail, 5/8" rebar | 1 | 11", 28" above the deck, off the back of the cylinder upright |
| Rod-tube lower rail, 5/8" rebar | 1 | 11", 4" above the deck |
| Side rail, 5/8" rebar | 1 | 29", 31" above the deck, between the two end posts |
| End hooks, 5/8" rebar | 4 | 2" out past the end with a ½" upturn: 2 leads, 1 helmet, 1 power cable |
| TIG rod tubes, 1½" Sch 40 PVC | 5 | 40" long, glued cap on the bottom, slip cap on top |
| Cylinder chains | 2 | About 36" each, hooked to eyes on the back of the cylinder uprights |
Weight and height
The finished cart weighs about 68 lb in frame tube plus 45 lb of deck and pads. With the casters recessed into the frame, the deck top sits about 6⅞" off the floor and the frame clears the floor by about 4¾". The caster pocket guide explains how that works with 6½"-tall casters.