Mobile Welding Table with Hangers and Bottom Shelf

 

After starting to learn to weld, I quickly realized I would need a welding table to clamp and work on projects.  After researching options and features in various stores, I decided it might be more interesting to build my own from scratch so I could have exactly what I wanted and also gain a lot of experience welding by just putting it all together!

As an engineer, I always like to start by sketching out the basic design with the features I want and that also feeds into a material list and a cut list.  For this table, I decided I wanted wide slats for the top with spaces in between to allow clamping projects from almost any angle.  From there, I also wanted a couple of side hanger bars, a full bottom shelf for storage, and finally heavy duty adjustable casters with wheels and feet to allow easy movement and stable work positioning anywhere on my nonlevel garage floor.

With my material list complete, I was able to send an order to my local metal supplier for the total uncut pieces I needed and then run down and pick them up.  After that, a few hours with my cold chop saw and I had all of my tubes cut and ready to start the build.

I struggled a bit trying to get pieces clamped up and square on my garage floor (you really need a welding table to make a welding table), but fortunately my neighbor is also a welder and loaned me his Fireball Tool Minion squares... and they were a lifesaver.

I've found from my woodworking projects to start with the top frame (which needs to be 100% square) and then build down from there I can usually handle any minor variances at the bottom due to slight bends, warps, etc.  A bit of time clamping and welding later (and some angle grinder time to make me the welder I "ain't") and I finally had a square top frame ready for legs.

Once again, I found myself fighting to get square (now in 3D space with legs), nut the Minion squares turned out to be the key to regaining my sanity and moving forward!  As soon as I had this first leg squared up and ready to weld I went ahead and ordered a pair for myself!

Once I finally had all four legs welded up and square, I added another vertical tube to help support the top slats and then it was time to start building the bottom frame for my shelf support.  

After the work squaring up the top frame and legs, the top center support and bottom shelf frame came together pretty quickly.  I also added some horizontal hanger bars so I could hang my angle grinder, clamps, etc. and have them out of the way, but also close at hand.

To mount the adjustable casters, I cut down some of the metal slats to size, drilled corresponding holes for the bolts and nuts and then finished shaping the slat to match the caster shape with a belt grinder.  It was a bit of work, but I was happy how they turned out.

From there it was just a matter of welding the feet to the bottom of each leg to securely mount the casters.

Once the feet and casters were complete, the project became much easier since the table was mobile (and very heavy).  From there I cut the expanded metal sheet for the bottom frame to provide storage, but realized I needed a bit more support so I cut and welded an inside cross frame support before welding on the expanded metal sheet.  Finally at the top, I spaced and welded on each individual top slat.

Once I finally had it all welded up, I had my first major learning point as I had to strip all of the mill scale for painting.  Next time, I'll definitely strip first to minimize the pain with connected angles and joints :)  Finally, I had to mount some of my equipment just to see how it looked before paint!

For the paint job, I put together a makeshift paint booth with cardboard.  I didn't want the top slats painted since I'd obviously be welding on them, so I used cardboard and masking tape to protect the slats and then my lovely wife (who is a much better painter than I am) painted the table from both top and bottom sides to provide good access and coverage.

For the final touches, I picked up metal polishing wheels and polished the top slats to a shine.  From there, I tested a couple of ideas to keep the bare metal slat tops from rusting and ended up with a simple WD40 spray and wipe since it seemed to work as well as other methods and was by far the easiest.

 I'm very happy with the final results and it easily holds all of my metal clamps, squares, tools, etc. so I can quickly roll it out to work and back into a corner to get cars back in the garage.  Next project, a welding cart so my welder and welding gas tank can join it in mobility :)