How to Build a Welder Cart

Building the Cart Frame

• 1

  Cut the 2-inch square tube into two 27-inch long pieces, two 12-inch long pieces and one 10-inch piece with a metal cutting bandsaw. Bevel the tubing on all ends at a 45-degree angle.

• 2

  Place the 27-inch and 12-inch pieces together to form a rectangle. Place the 10-inch piece 6 inches aft of the center of the rectangle. Weld the pieces together with a MIG welder.

• 3

  Drill and tap three holes at each end of the front of the cart with an electric drill. Bolt the front casters onto the cart and use a socket wrench to tighten the bolts.

• 4

  Weld the half-inch axle directly to the rear of the frame. Make sure the wheels remain free during the welding process. Weld four small metal braces diagonally across the frame and center brace. These pieces will act as supports for the bottom shelf.

• 5

  Measure the length and width of the area inside of the frame and ahead of the center brace with measuring tape. Use these dimensions to cut out a piece of plywood and a sheet of rubber. Lay the plywood down on top of the supports, then lay the rubber down on top of the plywood.

• 6

  Cut the 1.5-inch square tubing into two 22-inch long pieces. Bevel the tops of the pieces at a 15-degree angle. Position the upright pieces over half of the frame and half of the center brace. Weld the pieces into place.

• 7

  Weld the 19.5-inch by 10-inch wide top plate onto the upright pieces. Cut a small length of 1-inch square tube and weld it to the middle of the two upright pieces for added support.

• 8

  Cut a long length of 1-inch square tube to act as a brace for the top tray. Bevel one end at a 45-degree angle for the 1-inch square tube brace. Bevel the other end at a 15-degree angle for the underside of the top plate. Weld the 45-degree end to the 1-inch brace and the 15-degree end to the underside of the top plate.

Installing the Accessories

• 9

  Build the cable reel by drilling and tapping a hole in the center of the 5.75-inch diameter disks. Drill and tap another hole on the outside edge of the outer disk for the brass handle, then attach the handle to the reel with a 0.25-inch hex head bolt.

• 10

  Drill and tap a hole in the inside of the inner disk for the welding cable. Bolt both disks to each end of the 2-inch diameter pipe with a 0.375-inch long bolt to create the reel. Weld the sides of the reel to the center pipe.

• 11

  Drill and tap a hole for the 0.25-inch bolt at the end of the 0.375-inch diameter reel shaft. Weld the shaft onto the center right side of the angle iron bracket. Place a piece of thick rubber between the bracket and top plate, then bolt the bracket onto the top plate.

• 12

  Install a small spring and washer onto the 0.375-inch diameter shaft. Mount the reel onto the shaft and bolt it into place with the 0.25-inch bolt. Attach the #6 welding cable to the reel with a 0.25-inch bolt.

• 13

  Mount the welder on top of the top plate. Attach the short ground cable to the bracket with a 0.25-inch bolt.