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How to Make a DIY Welding Table

The metal table is made for welding. It was designed with spaces in between the tabletop for easy access to a clamp that uses the flat bars as footholds.

 With a sizing of 125cm (l) x 75cm (w) x 90cm (h) and four caster wheels with brakes, this table is suitable for accommodating objects of varying sizes. It is also sturdy enough to withstand heavy objects while at the same time remaining movable.

Step 1: Materials that you will need:

38.1 x 38.1 mm square tubing 75cm x 4 pieces

38.1 x 38.1 mm square tubing 110cm x 1 piece

63.5 x 38.1mm rectangle tubing 125cm x 4 pieces

63.5 x 38.1mm rectangle tubing 75cm x 4 pieces

63.5 x 38.1mm rectangle tubing 63cm x 1 piece

100 x 6mm flat bar 75cm x 8 pieces

50mm caster wheels with breaks x 4 units

Step 2: Tools Required

  1. Drop saw
  2. Angle grinder and cutting disks
  3. Welding machine
  4. Spirit levels
  5. Set square
  6. Metal Paint and paintbrushes or Metal spray paint.

Step 3: Preparation

  1. Cut 45-degree cuts on both sides of the rectangular tubing using the drop saw. Do this for all 4 of the 125cm and 75cm rectangular tubes. You will have a total of 8 bars cut on both sides.
  2. Cut a straight cut for the 63.5 x 38.1mm rectangle tubing at a 63cm length.
  3. Cut straight cuts for all the 38.1 x 38.1 mm square tubing.
  4. Cut straight cuts for all the 100 x 6mm flat bars at 75cm lengths.

Step 4: Welding the Frame

  1. Align the 45 degrees cut rectangular tubing into 2 sets of rectangles with the 125cm bars as the length and 75cm bars as the width. Use the set square to ensure 90-degree corners. Weld and fill in the gaps.
  2. On one set of the rectangle, add the rectangular tubing vertically across the centre for added support of the structure. Use a spirit level to ensure that the surface is flat before welding. This rectangle will be the bottom piece of the table.
  3. Set a 75cm 38.1 x 38.1 mm square tube on each corner of the rectangle from the previous step. Use spirit levels to ensure that the bar is levelled before welding, as shown in the picture.
  4. Add the second rectangle on top of the structure from the previous step and fully weld them together.
  5. Flip the structure with the bottom facing upwards and place the caster wheels on each corner of the bottom. Weld them in place. It should look like as shown in the picture.
  6. Again, add the 110cm 38.1 x 38.1mm square tubing horizontally in the middle of the top rectangle piece as shown in the picture and weld it in place. Make sure that it is levelled with the top frame as this is where the flat metal bars will be placed and resting on.

Step 5: Welding the Flat Bars

  1. Place all the 100 x 6mm flat bars in position as shown in the picture. Space them out evenly and make sure a clamp can easily access through the gaps. In my case, they had a spacing of about 6cm in between each bar.
  2. When you are happy with the placing, start by tack welding the centre part of the flat bars first. After this, move on to tack welding the sides of the flat bar to the frame systematically. This is to prevent uneven warping of the metal.
  3. Fully weld the flat metal bars to the frame structure following the same sequence to prevent warping.
  4. Finally, grind off all sharp edges using an angle grinder to give it a smooth finish. Your table should now look something like the picture above.

Step 6: Finishing

To complete your table, you can choose to paint it with the colour of choice that suits your workshop. Further modifications are possible where needed such as adding handles for easy manoeuvring or adding a piece of plywood to cover the bottom of the table which can also act as a place to store items.

Congratulations! Your welding table is now complete and ready to take on your everyday welding jobs.