First project - what else could it be?

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I'vee been lurking (and learning) on here for a few months now and thought I would post some pictures of my first project. It's a continual work in progress and it has taught me a lot.I started with the bottom and realized that cutting the metal sloppily (like you might do with wood) meant I ended up with an out-of-square frame. It was minimal but enough to throw things off. Lesson learned: make sure the metals fit up tightly, clamps won't hold things perfectly.So for the top frame I spent much more time cutting and grinding to ensure the pieces fit snugly and sure enough, I got a perfectly square top. I also quit trying to be fancy with the welds and welded from the outside instead of the inside. Not only did the welds come out better but it meant easier setup for the next part which was adding the legs. Lesson learned: if it's not art use the most effective method and not the one you think is prettiest.Since I had welded the bottom pieces on the inside it meant the legs hit the welds when I placed them where I want it to go. Since I couldn't get the grinder in that tight corner to clean up the weld it meant I had to grind the legs to fit properly. A real pain in the butt. Lesson learned: Think through the entire build process before welding stuff together.Once the frame was done I worked on the wheels. I knew I was going to need to add mounting plates to the front but didn't have the metal I needed. I did have an old, long piece of flat bar that I found on the farm so I made the plates from 2 pieces that I welded next to each other. It didn't take long to clean up the metal and I ended up with a pretty decent mounting surface. I also used more of the flat bar to strengthen the frame and add a spacer for the rear wheels. Lesson learned: sometimes scrounging works just as well as buying something.Mounting the wheels meant drilling holes and bolting things together. I placed the front wheels on the mounts, marked some holes, and started drilling. Well the metal is much harder than wood and the first thing that happened was the drill bit "walked" off the mark sort of like a top will rotate and move along the floor. It was just enough that I was only able to get 3 of the 4 bolts in for each wheel. Not bad, but not good either. Lesson learned: use a punch to make a divot so the bit stays on the mark. Worked great for the rear wheels.Ok, now for some pictures... Attached Images
Reply:Nice looking cart. Are you going to put some expanded metal on the bottom shelf?  Yes, use a center punch to get the drill started and cutting oil to keep from burning up the bit. I welded my wheels on.Keep posting your progress, looks good.Lincoln Pro Mig 180Everlast PowerARC 200
Reply:Are you going to put something on there to keep you welder from getting knocked off?
Reply:Nice little cart.If you do not want to drill holes you can use the self drilling self tapping screws and skip the drilling part.Those self drilling self tapping hex head screws/bolts will go through 1/8 steel no problem.AWS certified welding inspectorAWS certified welder
Reply:Hey tj,To keep your welder fairly secure on your cart, do as Custer recommended & add some angle or straight material near the bottom of the welder to keep it in place. You don't want to have one of those "OOPS! by you or someone else. Here's a couple pics of some of the material I used to keep the units steady.Denny Attached ImagesComplete Welding/Machine/Fab. ShopMobile UnitFinally retired*Moderator*"A man's word is his honor...without honor there is nothing.""Words are like bullets.... Once they leave your muzzle, you cannot get them back."
Reply:Thanks for all the feedback! I feel like a sponge ever since I decided to learn how to work with metal. Always learning something.I did add expanded metal to the bottom shelf. That brings up a good question though: what's the best way to weld that sort of thing in? I just used a series of tacks but I know I saw or read somewhere about using a washer as a sort of spot weld?I definitely need to secure the welder better. I was thinking either screwing it down or adding rails to the sides. I'll definitely get that done this week!The next project is patch panels for an old Volvo 122S I am fixing up. I'll add a new thread for that!-Tom
Reply:On my cart, I located 4 holes on the bottom of my ProMig 180; two of them were on the side where the wire feeder is and I took the other side panel off and located one I could get at from there and the other one was too close to the transformer to use.  I drilled holes in the angle to match and used nuts and bolts to secure it in three places.  For the expaneded metal, my cart doesn't have any but for the bottom shelf of my welding table I just tacked it in enough places that I knew it wouldn't come loose.Lincoln Pro Mig 180Everlast PowerARC 200
Reply:I always wonder why people build a welding cart out of angle iron and set the top upside down and then weld something extra onto the top to make flanges?Why not just attach it with the vertical part of the angle iron side up?That way the welder wont fall off and nothing needs to be added to it.You get what you put in and people get what they deserve...
Reply:If possible,just add longer bolts to the rubber feet of the welder and use big washers to hold bolt heads on under side of expanded metal.It would keep it held down and still provide cushioning to the welder.Last edited by dugndeep; 03-06-2011 at 10:54 PM.Maxus Pro-125 MigChicago Electric 90 amp DC flux-coreLincoln Electric AC 225 tombstoneO/A torchM/O mini-torch10 acres of flatland15 acres of holler
Reply:Originally Posted by brslkI always wonder why people build a welding cart out of angle iron and set the top upside down and then weld something extra onto the top to make flanges?Why not just attach it with the vertical part of the angle iron side up?That way the welder wont fall off and nothing needs to be added to it.
Reply:nice work, good to see you are trying and learning lessons. i have learned that  when you discover that something doesnt fit, or needs more grinding, or has been cut a bit short, it is helpful to say "miserable stinking whore bitch"...
Reply:Originally Posted by tjzelick I feel like a sponge ever since I decided to learn how to work with metal.-Tom
Reply:Originally Posted by weldbeadnice work, good to see you are trying and learning lessons. i have learned that  when you discover that something doesnt fit, or needs more grinding, or has been cut a bit short, it is helpful to say "miserable stinking whore bitch"...