first post, need opinions on bench design

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Well, I'm new to the forum and new to welding for that matter.  Getting ready to tackle my first big project, a welding table.  The height, width and length are pretty much set as this is replacing a wooden bench in my shop and will have to serve the same purpose plus the new welding chores.  I will also be building another 4'x4' bench to replace a wooden bench.  The bench will be mounted on casters and have leveling/locking feet.  I am attaching the iso view in sketchup for reference.  I'm planning to use 0.120" wall legs (4"x4"), 0.120" rectangular tube (2"x4") for the long rails and 3/16" wall 2.5"x2.5" square for the short rails so that I can mount my vise and other various tools as needed.  my shop is a two car garage that holds the wife's car and my tractor so everything has to serve multiple purposes and be mobile.  The cut out in the top of the table is for wood working tools that are mounted on 3/4" MDF (miter saw/planer/router table/etc).  I found a piece of 3/4" steel for the top at work so the cost will be great ($0.00 lol)  Will drill some holes in the top for jigs/fixtures also.  If I have grossly under or over sized anything let me know. Attached Imagesbig bench.pdf (23.6 KB, 447 views)
Reply:My opinion is you should build a welding table as big and heavy as you can afford.  You will end up doing heavier work than you think.  And with all the hammering and heating it will eventually see, bigger and heavier = better!Good luck and dont forget the pics!ECAVE Still learnin'Lincoln AC225Lincoln 135SPHF ChopsawVictor O/ANumerous other items
Reply:Looks like a good design, but... I would move the spreader up to at least the middle of the legs,  to make clearancefor feet, cords, junk on the floor, etc. Also it appears in the drawing that the legs are angled in (may or may not be true) I would just keep them straight, much easier to make and fix later if something happens.
Reply:I would attach some angle or rod across the supports to hold clamps and or grinders. Looks good. Welcome.
Reply:The legs are not angled in, just an illusion.  The bottom bar is as high as possible because there are "nesting" shelves on the wall where the bench sits to give me more storage.  ECAVE? What in particular do you think is not heavy enough? 3/4" top with chunky legs seems pretty solid to me but then again that is why I asked, I am open to ideas to make it better.Last edited by wvuredneck09; 10-30-2012 at 10:06 AM.Hobart 210 MVPEverlast Power Pro 256Best money I ever spent was on a welding class  MTEC
Reply:Oh I think it is plenty heavy.  I read your post as if you were asking if it is too heavy.Looks good to me.  Wish mine was more like your design.ECAVE Still learnin'Lincoln AC225Lincoln 135SPHF ChopsawVictor O/ANumerous other items
Reply:The receiver tube is great.  But keep in mind that the more of those you have along the front, the more they're going to interfere with clamping along that edge.  I'd want as much open space along the front lip as possible.  Also, remember that the square tubing won't be designed for tight nesting, since there's a seam inside it that will need to be ground down if you want a snug fit.  The other option is go go an eight down on the outside dimensions of the tube you slide into it.  (You can also buy stock without a welded seam in it, but it's more expensive.)Jack OlsenMy garage website
Reply:Originally Posted by Jack Olsen.  (You can also buy stock without a welded seam in it, but it's more expensive.)
Reply:I was planning on using 3/16 wall 2.5 tube to allow the sloppy fit with weld on the tubes.  Instead of pins to hold whatever in I was going to weld two opposing nuts on the tubes to allow bolts to be tightened to take out the slop and retain whatever is attached.  Anyone else done this?  As for the smaller bench here it is, slots in the top mimic the wood bench which makes it nice when I'm bucking down a sheet of plywood so I don't cut my table.  Also allow for clamping. Attached Imagessmall bench.pdf (26.3 KB, 123 views)Hobart 210 MVPEverlast Power Pro 256Best money I ever spent was on a welding class  MTEC
Reply:While I think that the MDF insert for woodworking machinery is a good idea...it sounds like you are going to be piling up a lot of flammable wood chips in your welding area.  If you are making (and storing) a second bench anyway, why not make that your welding table and keep it away from woodworking?Otherwise, your bench looks sturdy enough.KevKevin / Machine_Punk from The Aerodrome Studio - Lincoln PowerMIG 210 MP - Meco N Midget w/custom welding station - Vintage Victor 100Current Projects: The Aerodrome Studio
Reply:On the fitting of the tube, a nut welded on will allow you to use a bolt to fix it in position.  I picked up some spare hand-tightening screws when I was getting some drill press parts, and they allow you to do it without a wrench.I used to have mounts like this all over my garage.  It seemed like a great idea, but what I discovered was that I didn't really move equipment around all that much.  I think I've got one receiver left.  My vises and bench grinders all have their own home that doesn't move.For me, it's the same thing with casters on a table.  I'd rather not move stuff around, even with a small shop.  But that might be a personal preference thing.Jack OlsenMy garage website
Reply:Hi, in my opinion, you never mix wood chips with a welding environment.......unless you can completely remove the wood chips and sawdust from the crevices around the shop you are creating a spark trap and a smouldering piece of sawdust can go un-noticed.BTW, you mentioned the welding table top is 3/4"thick....that's great, but I wouldn't have a centre piece for woodworking tools etc.......keep them and any wood away from the welding zone, unless you want to spend more time cleaning up the shop and bench just to do a simple welding job.In shops where wood is processed, there is always, as in everytime always, wood shavings, sawdust and wood pieces lying around on the floor and that's a no no for a welding environment.Make your wood working bench mobile so you can move it outside and make wood mess on the grass if necessary.......sawdust can be just brushed off onto the grass without a problem.The ideal woodworking bench has a 2" minimum top to absorb the impact from a wood chisel and mallet when you are making joints etc, and the 3/4" steel top for the welding bench allows you to temporarily weld clamps to it and then cut them off and angle grind the top clean again.Attempting to do any wood work on a welding bench soon has the wood looking all black and messy.Ian.
Reply:I understand the issues with doing both in the same space but that is what I have to deal with for now.  The steel piece that gets cut out will be put back in place when wood tools are not in use so that piece is not an issue and I have a dust collector system (small one) for my wood working tools already so there aren't a lot of wood chip laying around.  In a couple years I'm hoping to build a nice pole barn to do all of my hobbies in and then each will have their own space but until then I'll just have to watch the hot sparks/saw dust.  I wouldn't be doing both at the same time as I can't with this setup I'll either be welding or building something but never both at the same time.Hobart 210 MVPEverlast Power Pro 256Best money I ever spent was on a welding class  MTEC
Reply:how big is the lip on the table?ESAB Heliarc 252
Reply:^^^^^^^See post #5DannyMy SiteJust worrying 'bout what I can't get to today.
Reply:Originally Posted by BlauSchuhhow big is the lip on the table?
Reply:Originally Posted by wvuredneck09If by lip you mean overhang it is 4" on each side and 3" on the front and back as drawn, meant for it to be 3" both ways and will adjust the framing for that unless someone has some advise for more or less.
Reply:Is the floor going to be stout enough to hold this behemoth?? Don't want it to break thru the slab
Reply:HAHA it is a 6" slab so it should be fine, if not it is more of an excuse to hurry up and build my pole barn.Hobart 210 MVPEverlast Power Pro 256Best money I ever spent was on a welding class  MTEC