Has anyone made a welding cart?

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Just kidding! I've looked at about every single one on this site and a few others. Hundreds really. The nice part is I got a lot of good ideas. I was going to start by making a table but I found a 4' x 4' x 1" table that had been drilled and tapped with 1/2-13 holes and for $250 there was no way I could build it for even double that so I just bought it. So that left me with a Dynasty 200DX that I found on CL sitting on my floor. So I'm building a welding cart. Sorry, no Sketchup as I sketched it in Pencil - an older program that I don't think is being made anymore since they quit updating it long before I was born. I digress. I wanted something that would hold the Dynasty and the cooler and maybe the Hypertherm that I was looking for. I don't have too many photos as I just started building but here's the table and a few shots of where I'm at so far. Still lots to figure out. I wanted foam filled wheels that work like pneumatics as I hate when the pneumatics go flat but I like how that roll - so I went foam filled. That's how I roll. And a longer view of the bench. It was a little rusty but I was able to chase all the holes with a tap and they're good but I'd like to get rid of some of the surface rust. I tried Naval Jelly but I'd like to find something better. Here's some of the welds. I'm learning as I go. Thick stuff is easier but I blew a hole into that top tube when I tried to tack it. Still getting the feel for this. This is the tube to hold the axle. Maybe I should have come up with a better way but I wanted to try to weld it onto the flat tube. It was really hard. I sharpened the tungsten to a needle point and extended it to reach into the gap. It's hard to get the flow going into such a narrow gap.Other angle - little better. For these inside joints I found I could basically flow them together without any or at least very little rod. Is that a bad thing? I figure the major welds are on the top and bottom so this is just to seal them. I should probably finish that corner.And that is the basic frame. The inner bars are for support and to hang the hooks for the cables. I want all the cables, cords and wires to be inboard so the whole thing is a compact box. Debating a small shelf or cubby for consumables.I also got the chance to try out the Hypertherm Powermax 30 today for the first time - another CL find - and since I haven't run 220 to my space yet it seemed to struggle to cut the 1/8" sheet at 110v. I suppose I'll need to run that power soon but it also makes a real stink so I doubt my shopmates will be keen on me using it. We'll see. Anyway, there's the bottom in place. Considering using 1/4" on the top so it will be more durable but I think 1/8" will be fine. I want the top to be a mobile surface so I can roll the cart up to a bike and weld on it right there. I'll post more shots when I get around to finishing it in the next week or so. Thanks to all the carts that came before me - I couldn't have done it without you!GPS Is it just me or my browser that seems to cut off all the text and photos to the right? I added returns so the words wouldn't get cut off but the photos are all cropped right? Is that a setting?
Reply:Originally Posted by sakuramaPS Is it just me or my browser that seems to cut off all the text and photos to the right? I added returns so the words wouldn't get cut off but the photos are all cropped right? Is that a setting?
Reply:You studied "hundreds" of cart designs to come up with that?Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:Why didnt you tie in all your welds? It looks kinda "weak".You have to learn the rules of the game. And then you have to play better than anyone else. Albert Einstein
Reply:Some of the shots are mid weld like the axle tube. I will finish tying them together but I wanted to get home for turkey. "Hundreds?" maybe - it was 11 pages of search results. I also didn't say I was going to reinvent the wheel - or that I was finished either. Like most first projects it's a learning experience. I have a lot to learn but I'll keep practicing. I also want to use it for a while to see what I like or don't like and then make some adjustments. G
Reply:Couple things I see.  You mentioned not tying in the welds yet.  They will probably be fine for that cart the way they are, but certainly wouldn't hurt to be tied in.  You really need to get into the habit of tying them in as you go.  Takes a bit of coordination to get the torch to follow around the corner, but with enough practice, it comes fairly easy.Secondly, it's hard to tell for sure in the pics, but the close up of the fillets shows a little undercut.  Your statement of not really using much filler further shows this.  You really need to shove more filler in the puddle as you go, to eliminate that undercut.  Cracks are very likely to form along the undercut edge.Who is John Galt?
Reply:Originally Posted by bassboy1Couple things I see.  You mentioned not tying in the welds yet.  They will probably be fine for that cart the way they are, but certainly wouldn't hurt to be tied in.  You really need to get into the habit of tying them in as you go.  Takes a bit of coordination to get the torch to follow around the corner, but with enough practice, it comes fairly easy.Secondly, it's hard to tell for sure in the pics, but the close up of the fillets shows a little undercut.  Your statement of not really using much filler further shows this.  You really need to shove more filler in the puddle as you go, to eliminate that undercut.  Cracks are very likely to form along the undercut edge.
Reply:sakurama, don't pay any attention to Sundown. I've not seen him make a positive post yet. As for tying in the welds and the undercutting, yes and yes. However, it will be holding a whopping 20 lbs, so it's not going to fail, but its something to build off of for future reference. For a first project it looks great, and I thought your welds looked good minus whats already been said.
Reply:looks better than a lot of carts I have seen.Nice work.PS,, will it "light up" those racing slicks LOL
Reply:Just a thought dude, your tank rack section looks like you have to lift the tank up and drop it down inside. You may want to leave the back open and either strap or chain the tank in. Or make the back hinge maybe . Just my 2cents.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:Originally Posted by dumb as a stumpJust a thought dude, your tank rack section looks like you have to lift the tank up and drop it down inside. You may want to leave the back open and either strap or chain the tank in. Or make the back hinge maybe . Just my 2cents.
Reply:beads look good.. i look at a weld  im fixing to make and concentrate on the corners. making sure i am in a good enough position to make the turn, i try never to stop before a corner..2 cents... tig or stick...
Reply:Originally Posted by bassboy1You really need to shove more filler in the puddle as you go, to eliminate that undercut.  Cracks are very likely to form along the undercut edge.
Reply:Why would anyone in their right mind make a welding cart when they can be store-bought just about everywhere!  What a waste of time!I have seen a lot of carts here...  and will probably make one eventually.  The store-bought one Santa Clause brought me a few years ago works, but lacks character and acouterments.  I had to add on my own handle because it didn't have one. Confession:  I made a U-bend in a length of 3/4" EMT and .......  and ah, hem...  I uh.....  bolted it on.Keep us posted on the progress!  I'd like to see yours finished and put to work!-MondoMember, AWSLincoln ProMIG 140Lincoln AC TombstoneCraftsman Lathe 12 x 24 c1935Atlas MFC Horizontal MillCraftsman Commercial Lathe 12 x 36 c1970- - - I'll just keep on keepin' on.
Reply:Great job for your first project especially since you're learning as u go. Keep the pix coming
Reply:this is  the cart i made with my 250 ex everlast and took it to work and powder coated it. Attached Images
Reply:Originally Posted by sakuramaJust kidding!  Sorry, no Sketchup as I sketched it in Pencil - an older program that I don't think is being made anymore since they quit updating it long before I was born. I digress.
Reply:i made one for a dx200 and a water coolernever bought a cooler so i have my 375 there Attached Images
Reply:ed that is a great looking cartI need to fix mine up a lil puts mine to shame.“I'm going to do the thing that God put Galen Beasley on this Earth to do:Have Salon quality hair and weld.Nothing like a good cup of coffee and the smell of 6010 burning in the morning. 971-204-3444 cell API ASME Structural NDT and Repair
Reply:One of the first things I made was a cart for my shinny new Lincoln welder. I got the cart together and it continues to work without falling apart but that project showed me just how much practice and learning I have ahead of me! The link below is to a story on building my welding cart.Building My Welding CartTom Hintz, publisherwww.newmetalworker.comLincoln Pro Mig 180Lincoln AC 255Determination
Reply:nice, that is a positive way to start welding, by building something useful, koolSteve Hot Rod HooliganMiller Maxstar 200 STRCampbell Housfeld Flux Core 80
Reply:I built mine with the idea of having two tanks....one for C/25 and one for pure Argon. Both 125 Cft. tanks.  I also included two shelves. One for my mig and one for my tig. I can switch the Argon tank with the C/25 in case I want to mig weld aluminum. But seeing how I have a tig, that usually does not come up much. My 5 inch wheels are from Tractor Supply and each one can handle 350 pounds. Two are casters and two are fixed. Two of the biggest mistakes I have seen with home built carts is too small of a wheel to overcome cracks and bumps and too light a wheel for the weight. Another mistake is not having any caster wheels. It sure is funny watching somebody trying to turn a cart when the wheels are all pointed in one direction!  It sure is nice having a cart that has all my welding equipment together and easy to move around. It was fun to build and I can say I built the thing myself.
Reply:Haven't had much time to work on this but I've got it to the useful stage now. Here's some of the additions since last time: Hooks for the cables:Handle that has started to double as a place to wrap the torch cable.Holders for the Rod Guard tubes. I was going to make tubes but this was just easier. Replaced the bolts with hand screws:The second argon fitting is a push to fit adapter for purging tube. And the where it's at now: Thinking about a pedal holder mostly I want to paint it and be done. G
Reply:Thats turning out really nice!Millermatic 251Spectrum 300 PlasmaEverlast PowerTig 250EXEverlast PowerCool W300Harris / Victor OACraftsman 13 Speed Drill PressProTools Air/Hydraulic Bender48" BrakeCompressor, Notchers, Grinders, etc.
Reply:where did you guys get the leather wraps ??Think I got it from Cyberweld.com. I got a fabric one specifically for my torch but it was 10' and my leads are 12' which bugged me. The leather has snaps which can still be snapped doubling up any excess at the end and now the whole thing is covered.
Reply:Originally Posted by nitrosportmanwhere did you guys get the leather wraps ??