New Welder's First Table (long)

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Hey guys!  I'm new here, and new to welding in general. I learned to weld with OA when I was a kid, and did a little stick later on, but have been away from it for a while. We bought our house last year and it had a 40x70 pole barn attached to it. I got interested in knifemaking and general blacksmithing, and have been slowly accumulating tools over the past year.  I sold my motorcycle and bought a four year old Lincoln AC/DC with a TIG torch attachment for $300.  I went home and had Dad give me a refresher, but I'm a long way from where I need to be. First thing first, I need a table.  I'm a paramedic in town and one of our students doing ride time is a machinist at a local factory. They were throwing away a perfectly good small table, so he snagged it for me. Cleaned it up and painted to match. It's a nice table for practicing, but really a bit too small for much of anything larger/longer.  It's overbuilt though, which is nice. This is where the story will seem to go off track, but stay with me. One of the local hospitals landed a big contract and they are remodeling. In the dumpster outside the ambulance bay were a BUNCH of suspended ceiling lights. I had to go all the way up to the CFO, but I got permission to salvage the lights.  It took me three trips over a week and a half, but I scored all these lights. There are 28 4 ft fixtures and 15 2 ft fixtures. All are 4 bulb fixtures and have all the bulb in them. I also scored around 30 extra 2 and 4 ft bulbs out of unsalvageable lights. My goal was to keep at least a dozen-ish big lights for my shed, and half a dozen or so little lights. The rest, well, they are trading fodder. Remember, I wanted to make a welding table. For my first trade, I swapped the car detailer guy down the street four 4 ft fixtures for this list.  All new, non rusty steel. I had thought the long pieces of angle would be decent legs and part of a top frame, and I could build it slowly as I salvaged more steel. You see, we have 5 kids, and my wife works her *** off at home with them, so my check doesn't go real far towards hobbies that don't make money. One of our other students at work has a brother who works at a local grain cart manufacturer.  Apparently one of the brothers coworker's needed some lights for his shed. I traded him a dozen 4 ft lights for a piece of steel for the top.  I hadn't decided the dimensions yet, so it was kind of a "to be determined" type of trade.  Every third day on my way home, I pass a guy's house that is.......a junkyard, putting it nicely.  My kind of picking!  I never could catch him home, so I finally left a message on his car and waited. He called me a week later. After some haggling, I bought this frame for $25. It is 1 1/2" 3/16" angle. I called in my favor and got the steel for my top. It's 64"x32" which will give me a 4" overhang on all sides. This is the piece of steel for the top. It was supposed to be 1/4", but when I piled it up, it was 3/16".  I'm not really in a position to argue about it, as it was free anyway!  Haha
Reply:Here's where I'm at now. I cut the back upright off and am in the process of using a flap disc to take off the paint. Here is my proposed plan for the table. The notes about "heavy angle" are just my way of differentiating between a couple different sizes of angle I have on hand. So far, I have $25 in my table. I'm left handed, so I've a shelf on the left for hammers and clamps and not on the right. The right shelf is bigger for small scraps and fixtures. Here is my dad's table, the one I learned on when I was a kid. He went to college for welding and he has farmed all his life. This thing has seen some serious action.  He has a Hobart MIG he uses primarily now, but that Lincoln has seen a lot of welding time. So, if you're still with me, I'd love to hear opinions, critiques, attaboys, whatever. I look forward to learning lots here!  Oh yeah, one more. I stopped by the local machine shop/fab shop/steel supplier today to raid their drop bin for some practice coupons. Here's what I got for FREE!!!Those 60 3x5"x 3/8" coupons will need cleaned up a bit before practice, but I can handle that!  I want to make a new entryway step for my shed door from the 4" angle.
Reply:I like the pipe upright on dads bench (for clamping or whatever) good idea. Yours looks good so far, but you need to get it dirty (character) soon.Miller thunderbolt 250Decastar 135ERecovering tool-o-holic ESAB OAI have been interested or involved in Electrical, Fire Alarm, Auto, Marine, Welding, Electronics ETC to name a just a few. So YES you can own too many tools.
Reply:You got a few good deals there. But if the hospital there is like the one I work for those lights run on 408 3 phase, and will require you do some rewireing to make them work. And the ballast will need to be changed out as well. Just trying to give you a heads up before you get them up and find they don't work.Offering CNC Plasma cutting and welding projects.Follow me on facebook https://www.facebook.com/nobigdeal.fabSupport those that support WW.
Reply:Originally Posted by NoBigDeal FabYou got a few good deals there. But if the hospital there is like the one I work for those lights run on 408 3 phase, and will require you do some rewireing to make them work. And the ballast will need to be changed out as well. Just trying to give you a heads up before you get them up and find they don't work.
Reply:Thanks guys. I did take one of the lights and "plugged it in" to an extension cord on 120VAC. It popped right on, but I may have gotten lucky and found a single one that works. Regardless, my trading has netted me some usable equipment, so if they don't work I'll be disappointed, but not horribly upset. Any ideas how to tell exactly how these lights are voltage-wise, without tearing every single one apart?  Will the bulb type give it away?
Reply:Only way is to look at the ballast itself. If it was an older hospital they may be 120.
Reply:It is a pretty old hospital, I'll tear a couple open and check out the ballasts.
Reply:They are 120VAC. They are lit up in this picture via the wires in an extension cord.
Reply:Ok, here's where I'm at now. I didn't get enough flap disks, so I'm about 20-30 worth of sanding away from being ready to start marking and cutting. Sucks, because I had the time to mess with it tonight, but didn't have the equipment. Hate when that happens!I changed the plans a bit. I'm going to run angle for the front and rear middle legs. I have a couple questions though.   On the front, I'm going to use a piece of thin wall square tube for the top shelf support. The shelf is pretty narrow top to bottom, so this will keep it from having an annoying lip. I plan to keep my slag hammer and electrodes on that shelf and don't want to have to reach over a lip every time. Can I just cut a short piece of tube, weld it into place, and cut the next piece of tube and weld into place for the front support?  On the back, I planned to use a piece of angle for the shelf support. How do I run a angle across, a angle down, and an angle through?  I am having issues picturing it. Basically, the front left center leg has one piece of tubing running perpendicular to it. The back left middle leg has two pieces running perpendicular through it, and the back right middle leg has one piece running perpendicular through it. Maybe a picture will help?
Reply:Your thread shows how much fun the process can be, I find that if you ask most people will be happy to get rid of their trash, just to get it out of their sight. Great way to connect with others,too. Enjoy the trip. BTW, if you resize your fotos down, we'll be able to read all of your story, the size of them is enlarging the post beyond the site's display frame. Look forward to seeing your table finished  Last edited by bearston; 06-03-2012 at 12:54 PM.When a welder tells you to "stick it", what do they really mean?"In a time of universal deceit, telling the truth is a revolutionary act." - George Orwell
Reply:Well fooey. I'm posting from my phone-Tapatalk.  How much Is getting cut off?
Reply:I think that shrinking those fotos 15% to 20% will do the trick fer shure!When a welder tells you to "stick it", what do they really mean?"In a time of universal deceit, telling the truth is a revolutionary act." - George Orwell
Reply:Apparently I can't go back and edit pictures or posts once they are written? Edited to add:  Apparently for only a short time.   I have to figure out a way to resize pictures posted from my phone.Last edited by Brian.Evans; 06-03-2012 at 04:05 PM.
Reply:Hey guys!  I'm new here, and new to welding in general. I learned to weld with OA when I was a kid, and did a little stick later on, but have been away from it for a while. We bought our house last year and it had a 40x70 pole barn attached to it. I got interested in knifemaking and general blacksmithing, and have been slowly accumulating tools over the past year.  I sold my motorcycle and bought a four year old Lincoln AC/DC with a TIG torch attachment for $300.  I went home and had Dad give me a refresher, but I'm a long way from where I need to be. First thing first, I need a table.  I'm a paramedic in town and one of our students doing ride time is a machinist at a local factory. They were throwing away a perfectly good small table, so he snagged it for me. Cleaned it up and painted to match. It's a nice table for practicing, but really a bit too small for much of anything larger/longer.  It's overbuilt though, which is nice. This is where the story will seem to go off track, but stay with me. One of the local hospitals landed a big contract and they are remodeling. In the dumpster outside the ambulance bay were a BUNCH of suspended ceiling lights. I had to go all the way up to the CFO, but I got permission to salvage the lights.  It took me three trips over a week and a half, but I scored all these lights. There are 28 4 ft fixtures and 15 2 ft fixtures. All are 4 bulb fixtures and have all the bulb in them. I also scored around 30 extra 2 and 4 ft bulbs out of unsalvageable lights. My goal was to keep at least a dozen-ish big lights for my shed, and half a dozen or so little lights. The rest, well, they are trading fodder. Remember, I wanted to make a welding table. For my first trade, I swapped the car detailer guy down the street four 4 ft fixtures for this list.  All new, non rusty steel. I had thought the long pieces of angle would be decent legs and part of a top frame, and I could build it slowly as I salvaged more steel. You see, we have 5 kids, and my wife works her *** off at home with them, so my check doesn't go real far towards hobbies that don't make money. One of our other students at work has a brother who works at a local grain cart manufacturer.  Apparently one of the brothers coworker's needed some lights for his shed. I traded him a dozen 4 ft lights for a piece of steel for the top.  I hadn't decided the dimensions yet, so it was kind of a "to be determined" type of trade.  Every third day on my way home, I pass a guy's house that is.......a junkyard, putting it nicely.  My kind of picking!  I never could catch him home, so I finally left a message on his car and waited. He called me a week later. After some haggling, I bought this frame for $25. It is 1 1/2" 3/16" angle. I called in my favor and got the steel for my top. It's 64"x32" which will give me a 4" overhang on all sides. This is the piece of steel for the top. It was supposed to be 1/4", but when I piled it up, it was 3/16".  I'm not really in a position to argue about it, as it was free anyway!  HahaRepost of first post.Last edited by Brian.Evans; 06-03-2012 at 04:18 PM.
Reply:Here's where I'm at now. I cut the back upright off and am in the process of using a flap disc to take off the paint. Here is my proposed plan for the table. The notes about "heavy angle" are just my way of differentiating between a couple different sizes of angle I have on hand. So far, I have $25 in my table. I'm left handed, so I've a shelf on the left for hammers and clamps and not on the right. The right shelf is bigger for small scraps and fixtures. Here is my dad's table, the one I learned on when I was a kid. He went to college for welding and he has farmed all his life. This thing has seen some serious action.  He has a Hobart MIG he uses primarily now, but that Lincoln has seen a lot of welding time. So, if you're still with me, I'd love to hear opinions, critiques, attaboys, whatever. I look forward to learning lots here!  Oh yeah, one more. I stopped by the local machine shop/fab shop/steel supplier today to raid their drop bin for some practice coupons. Here's what I got for FREE!!!Those 60 3x5"x 3/8" coupons will need cleaned up a bit before practice, but I can handle that!  I want to make a new entryway step for my shed door from the 4" angle.
Reply:Ok, here's where I'm at now. I didn't get enough flap disks, so I'm about 20-30 worth of sanding away from being ready to start marking and cutting. Sucks, because I had the time to mess with it tonight, but didn't have the equipment. Hate when that happens!I changed the plans a bit. I'm going to run angle for the front and rear middle legs. I have a couple questions though.   On the front, I'm going to use a piece of thin wall square tube for the top shelf support. The shelf is pretty narrow top to bottom, so this will keep it from having an annoying lip. I plan to keep my slag hammer and electrodes on that shelf and don't want to have to reach over a lip every time. Can I just cut a short piece of tube, weld it into place, and cut the next piece of tube and weld into place for the front support?  On the back, I planned to use a piece of angle for the shelf support. How do I run a angle across, a angle down, and an angle through?  I am having issues picturing it. Basically, the front left center leg has one piece of tubing running perpendicular to it. The back left middle leg has two pieces running perpendicular through it, and the back right middle leg has one piece running perpendicular through it. Maybe a picture will help?
Reply:Brian, looks like you have done real good on your trading. I was wondering do you happen to know what the name brand is on the tig set up that you got with your stick welder? Have you tried it out?
Reply:Originally Posted by gnewbyBrian, looks like you have done real good on your trading. I was wondering do you happen to know what the name brand is on the tig set up that you got with your stick welder? Have you tried it out?
Reply:Got the legs and shelf supports all cut to length. I have to get my 240V outlet switched to one compatible with my welder and I'll beready to start fabbing!  Hopefully I can go find one tomorrow.Last edited by Brian.Evans; 06-03-2012 at 09:00 PM.
Reply:Also, now accepting color and primer/paint suggestions. I don't have a HVLP gun or air compressor, so will need either rattle can or brush on. I'd like it not to be black.  I need a rust preventative primer as there is still a bit of rust I can't get sanded off. So far I've spent:$25--frame$20--flap disksStill need paint and primer.
Reply:I'm using Forrest green for everything in the shop because it's diffrent......Offering CNC Plasma cutting and welding projects.Follow me on facebook https://www.facebook.com/nobigdeal.fabSupport those that support WW.
Reply:Originally Posted by NoBigDeal FabI'm using Forrest green for everything in the shop because it's diffrent......
Reply:Brian, I have pretty much the same stick welder you have, you will probably want to make you a wheel set up for your welder before long. The short leads don't allow you to move around much. I have a 40-45' extention cord I use between my welder and my wall plug end.
Reply:I can't remember. I'll have to look at it tonight. I'll get back to you on it.Here is a link to a workbench I did. It shows the color. If you like it I'll get you the color and brand off the can. I have about 8 cans left and about 6-7 primer. So I'll be painting stuff green for a long time to come. LolLast edited by ★ NoBigDeal Fab ★; 06-04-2012 at 12:42 PM.Offering CNC Plasma cutting and welding projects.Follow me on facebook https://www.facebook.com/nobigdeal.fabSupport those that support WW.No link mate. Try again, I'd like to see it.
Reply:Here it is.http://weldingweb.com/vbb/showthread.php?t=126701Also the paint I used it rustoleum professional high performance enamel. In "hunter green" the color code is 7538. I also used the same for primer. (professional) hope it helps.Offering CNC Plasma cutting and welding projects.Follow me on facebook https://www.facebook.com/nobigdeal.fabSupport those that support WW.
Reply:I got a little bit more done this morning. If I could get an hour or two of straight work in, I'd be able to get the frame finished. Sigh.....such is life with a family.  Maybe I can work on it more tonight. I'm happy with it so far. The opening was supposed to be 24", and it is 24 1/16" along it's entire front to back length, which makes me very happy.Last edited by Brian.Evans; 06-11-2012 at 03:06 PM.
Reply:Family sucks that way sometimes, but that's life. They just gotta learn to stay out of the way and let you have a hobby. (disclaimer: I have 3children and a loving wife they take the front seat to any project no matter how big, i am just pullin your chain a bit)Offering CNC Plasma cutting and welding projects.Follow me on facebook https://www.facebook.com/nobigdeal.fabSupport those that support WW.
Reply:Originally Posted by NoBigDeal FabFamily sucks that way sometimes, but that's life. They just gotta learn to stay out of the way and let you have a hobby. (disclaimer: I have 3children and a loving wife they take the front seat to any project no matter how big, i am just pullin your chain a bit)
Reply:More done and a question that needs answered before I can go further. Please please watch the video. I'm not at all impressed with my vertical welding skills. Basically I suck donkey butt. Big donkey butt. My horizontal welds look good, but everything vertical looks horrible. I blew through the front shelf supports in a couple places. I had to use tubing because I was going to run out of angle.  I tried to run mostly on the angle and wash the puddle over to the tubing, and was only moderately successful. It don't look purty, but I got my 270 lb butt up on them and jumped up and down and both sides held, so it surely will hold rod and slag hammers and wire brushes ok. Here's the video. Thanks. http://redirector.googlevideo.com/vi...EFDEFB&key=ck1
Reply:Decided to say screw it and make the "back" the "front". Now I have to weld a piece of angle between the middle legs on the new back side. However, I used nice angle for the new front, and it looks really great, comparably. I think I could have had it done tonight, but my baby girl woke up, so now I'm inside rocking my sweetheart and not wishing I was welding even a little.   I have five pieces left to weld in. The support between the back middle legs, and the four cross members that will hold the top shelves. Then I have to cut the pieces of expanded metal for the shelves and clean up the welds/spatter and I'm DONE with the frame. The four cross members for the top shelf are going to be a pain, because they all have to be coped into place. It takes me a little while to get it right sometimes, but I'm determined to get it as right as I can, within my ability. All the legs are perfectly square down to 1/16-1/32" across their length, which I am very happy about. Better view of the top shelf supports. They aren't in their exact places, just thrown up there so you know what I'm trying to say.
Reply:Decided to say screw it and make the "back" the "front". Now I have to weld a piece of angle between the middle legs on the new back side. However, I used nice angle for the new front, and it looks really great, comparably.*I think I could have had it done tonight, but my baby girl woke up, so now I'm inside rocking my sweetheart and not wishing I was welding even a little.  *I have five pieces left to weld in. The support between the back middle legs, and the four cross members that will hold the top shelves. Then I have to cut the pieces of expanded metal for the shelves and clean up the welds/spatter and I'm DONE with the frame.*The four cross members for the top shelf are going to be a pain, because they all have to be coped into place. It takes me a little while to get it right sometimes, but I'm determined to get it as right as I can, within my ability.*All the legs are perfectly square down to 1/16-1/32" across their length, which I am very happy about.*Better view of the top shelf supports. They aren't in their exact places, just thrown up there so you know what I'm trying to say.*Last edited by Brian.Evans; 06-15-2012 at 12:39 AM.
Reply:All the shelf supports are coped to roughly fit and the rear middle leg stretcher is cut to fit. I can put the band saw up now and use the grinder for final fit up. I'm thinking only an hour or two of finishing up and final prep and I'm ready for primer and paint. Regarding the top:  I'm thinking I want to drill three or four holes down the long sides and use countersunk bolts through the angle below.  Would that work ok?  My top is 3/16 or 1/4". And I still need to figure out a damn color!!
Reply:So I take it you did not like my green idea.......Offering CNC Plasma cutting and welding projects.Follow me on facebook https://www.facebook.com/nobigdeal.fabSupport those that support WW.
Reply:It's not that, I just don't have any boots that go with green..............huh?  LolI have seriously, seriously toyed with the idea of flap disking it and clear coating the bare steel.  Only problem is then all my horrible welds show.  It would look neat though.
Reply:I was planning on having the frame done tonight, but took my middle daughter to see Madagascar 3 instead. Whhhooooollllle lot better than welding, even though I really enjoy working in my shop. Gotta love blondes with big blue eyes, watch your hearts, they'll steal them every time!
Reply:Was it good thought about taking my kids to see it. And green goes great with all boots..... LolOffering CNC Plasma cutting and welding projects.Follow me on facebook https://www.facebook.com/nobigdeal.fabSupport those that support WW.
Reply:Well, it was a little (lot) thin on plot.  Funny in parts, but not as much sideways humor or veiled adult jokes as the first two.  If you do go, see it in 3D. This was my first 3D movie and it was totally worth it. Fwiw, my daughter laughed her butt off.  It might have just been the slushie talking though........she was pretty high on iced sugar.
Reply:Got outside at a decent time tonight, which means I didn't have to work past midnight to make progress. And progress I did make!I was able to finish the shelf brackets quickly.  Having the coped out the other day really helped. Not having to switch back and forth from the grinder to the band saw saved mucho time.  I cut my expanded metal to fit. I think it looks decent. I dragged the whole thing to the middle of my shop floor and muscled the top into place. Then I put welder where it will sit just to get an idea of sizing. What do you all think?  I wish I had another piece of plate for the top, or a thicker piece, but free is free.I still need to attach the top. I am accepting suggestions. Also, I'm still deciding on a color.Last edited by Brian.Evans; 06-18-2012 at 12:24 AM.
Reply:I decided on red, to match my welder.  Big shock, I know. I had been playing with an idea in my head to make a modular system for holding a vise and possibly bending studs/holes for decorative iron work. This table is more than just a welding table, it my general metal work table as well. I started by painting a Littleton USA 4" vise I bought cheaply a long time ago. I didn't go hog wild with the paint because this is going to get banged up pretty good working with steel. Pieces of the nested tubing. They are a perfect fit, with some filing and grinding of course. The big tubing I got from the steel yard scrap bin, and the smaller stuff I got in my initial trade with the guy down the road. Placement of the holder, on the left side, near the front of the table. The following pictures show how everything will fit together. Of course, all of it will be welded, there will be a set screw/bolt on the bracket, and every thing will be painted black. Sorry they are such crappy photos. So, whatcha think?  I think it will work fairly well for light weight clamping and hammering. Nothing too much or it'll tip the table.Last edited by Brian.Evans; 06-18-2012 at 10:32 PM.
Reply:This is nice. Well done!Jupiter Weld & Repair -- www.Jupiterwelding.com
Reply:Looks great, but can I make one minor suggestion? Cut the tubing down a bit it will be hard to work arround that long piece sticking out..........Yeah yeah I know it mockup just giving you a hard time. LolOffering CNC Plasma cutting and welding projects.Follow me on facebook https://www.facebook.com/nobigdeal.fabSupport those that support WW.
Reply:Nice NBDF. Very funny.  I can't think of a witty comeback at the moment. I was able to get in out ambulance shop and use the torch to bend these brackets. They will be used for the stinger and ground clamp cables. They still need trimmed up a bit and I may have to shorten the upright to table connection point length a little as well.  I don't want to catch myself on them when I walk past the table.
Reply:Just left the hardware store. I got 6, grade 5, 3/8 fine thread bolts and the appropriate tap for the table top. I decided I liked drilling through holes in the frame and tapping the top  better than welding the top. I am afraid it would end up warping.  There should be 4.5 threads in the 3/16" top. I also got the bolts and nuts for the t-handled clamping mechanisms. Hopefully I can get them mocked up today or tomorrow.  I got the bolts for the vise as well, so hopefully I can get it done too.I'll do the final sanding/grinding on the frame and everything else over the next few days and then be ready for primer and paint!  Let's do this!!
Reply:It has been HOT here and we've been busy with finishing up softball season, so haven't had a chance to get out and work on the bench before tonight. I welded the lead brackets on and cleaned up the top edge of the middle shelf with the grinder.  I have a lead (no pun intended) on some used leads I can buy cheaply to extend mine. I can't afford $4.49/ft for lead wire. I'd been toying around with an idea for grinder and grinding wheel storage on the bench. I hate hunting around for my angle grinder and especially that stupid wheel/arbor wrench. I always lay it down and can't find it when I need it. I think I'm going to add another set of grinder hooks, because changing back and forth from cutting to grinding disks all the time is really annoying when I'm fabricating, and 4 1/2" angle grinders aren't all that expensive, even for decent ones, which I do not have yet. I almost have the vise mount and the first vice clamp done. I need to get a few more receivers filed down and welded on.  Sorry for the horrible pictures. I need to get those lights up soon!I couldn't find any oil, so I used Dawn for cutting fluid. It worked decent. Damn 118* drill bits suck. I couldn't find any 135* split points tue correct size at the hardware store though.
Reply:Well........Life got very busy with my wife intermittently being very sick and working both jobs and just plain raising a family!  I finally had time a couple weeks ago to go out to the shop and finish this table off. Here's the finished thing!I ended up just tack welding along the inside of the top rail. The top didn't warp, and it is secure to the frame, so it worked fine. I'm glad it's done. Now to get some wire and move the table and 220 outlet across my shop.........oh, and some longer leads as well.  Once that happens, I'll reroute the leads behind the table.