Noob weld cart build.
 

Hey Guys!

So, I know this isn’t really an XJ-specific project but it still seemed to fit the guidelines for the Fab section. I wouldn't even be starting this project if it wasn't for my XJ in the first place, so here we go! I recently purchased my first MIG setup, and now I’m working on my very first project—a multi-purpose welding cart!

A little background, the whole reason I purchased this welder is to fix the rust on my XJ. I also plan on doing 2x6 rocker sliders since my rockers are rusted out. I welded in shop class in high school about 8 years ago and figured this will be great practice for me to get up to speed before I actually start welding on the Jeep.

So I’ve had a lot of ideas about how to do this thing, and so far here is the current culmination of features:

• Red and Rustoleum Hammered finish
• Fire extinguisher mount
• Dual duplex power outlet panel on the front + dedicated outlet on the rear for welder (Logistics of that to be figured out yet)
• Diamond plate outlet covers w/ red outlets for visibility
• Mounts for other tools such as angle grinder, drill, etc.
• Possibly a drawer for misc. storage
• Ball-bearing pushmower wheels and locking front swivel wheels

So, also keep in mind that I will be basically building this thing with only the welder, an angle grinder, and a drill. :thumbup1: I don't even have a damn workbench! I also have very little as far as a plan goes and I’m basically winging it as I go. I started working on this yesterday, now for the goodies..

Here’s what I’m starting with after a trip to Tractor Supply…This is enough to begin the base of the cart. 1x1 steel, some flat iron, and I forget the size of the smaller bar that I’m going to use as a cross-grate type deal for support.
http://i1286.photobucket.com/albums/...ps1e4a7081.jpg

After some measuring and comparing to the box the welder came in, and mocking up some stuff on the garage floor with the welder itself, I came up with 28”x14.5” for the base. Getting ready for the first cut! My workbench is merely a 2x4 and a C-clamp :lol:
http://i1286.photobucket.com/albums/...ps86dd0808.jpg

First cut!
http://i1286.photobucket.com/albums/...psa3bcdc72.jpg

I started playing around with the various pieces I have to get a feel of how I’m going to attach the wheels while keeping it level as possible. I haven’t decided yet if I’m going to run the rear wheels right through the 1x1, or weld a sleeve onto the bottom of it yet. Either seems like it would work OK at this point. The rear and front wheels both have 3” from the “axle” or part that connects to the cart, and the point of contact with the floor.
Attachment 333893

The front wheels are 2x2”, so I will end up welding a 1” corner piece on the inside of the frame to support the wheels.
http://i1286.photobucket.com/albums/...psdb3daab2.jpg

More mock-up…
http://i1286.photobucket.com/albums/...ps39fe6186.jpg
http://i1286.photobucket.com/albums/...ps410d1d6f.jpg

Now that the cuts are done and mockup complete, time for the fun part—start welding it together!
http://i1286.photobucket.com/albums/...psf94f96a1.jpg

Overall, I don’t think I did *too* bad for having a shaky hand. I have a few more to do yet but so far it is very sturdy with these welds. I used the chart on the inside of the welder and it seems to be quite accurate. Arc voltage set at “F”, wire speed at 5.5. Critiques, tips, etc. welcome.
http://i1286.photobucket.com/albums/...ps1ca8219b.jpg
http://i1286.photobucket.com/albums/...ps4d0b7294.jpg
http://i1286.photobucket.com/albums/...ps3d81db7d.jpg

That’s all for now, I’ll be back on this later today!

Cool. That one end with the wonky angle cut threw me off in the pics. Looks like fun! The cart seems very tight for just the welder and gas, where did you plan on putting a receptacle exactly?

Looks good.

I so need to get around to building one of these, get my welder off the workbench.

don't forget about a few hangers off the side for gloves, helmet, wire brush, cables and other crap. looks like a good start.

same here. im so tired of carrying it where ever I need it. or bringing what i need welded to it...

I'd play around with the settings a little more, I'd also try slowing down a little or don't start your bead until you get a good puddle started.

Otherwise they look just like mine when I first started. Keep up the good work!

Thanks for the compliments, everyone! :cowboy:

LOL, it's hard to get a straight cut with nothing but an angle grinder and a 2x4. I've given myself some breathing room for tidying up the edges..should've done that before welding it I guess! :icon_cool: As for the outlets, I plan on putting them on the front of the cart, like this...

Attachment 333890
Excuse the poor drawing. The white space above the outlet panel I put there as a placeholder for a handle.

Oh, definitely. I will cross that bridge when I get to it. I originally was going to work from the top down, but decided to start at the bottom and work my way upwards. I'll need to figure out the handle situation also.

Thanks! I'll take heed to these tips. I hadn't started a puddle first, kind of went right into a bead. Do they look too hot to you, or maybe slow the wire speed a little? They seem to have penetrated well but it's hard to tell for a noob like me. :D

I myself like a higher wire speed. But if you're following what the chart saw then I think you're fine.

Starting the puddle is key. I like to start the puddle then go side to side. Some people prefer making circles. Try both and see what you like.

I do the same. start a good puddle then move side to side and walk the puddle and try to keep the same size the whole time.

Great first project! Definitely keep us updated with pics. You gonna build a welding table/workbench as well?

apparently he needs to. lol

Little e-whips are good too, kinda depends on what position you're welding in, keep playing with it, you'll get it...run some practice beads on any scrap material you have, and weld in flat, horizontal, vertical and overhead positions, you can't always move pieces around when working on some projects, and gravity can be a *****, LOL...Perfect makes practice...

:tongue_smilie:

Lol, I do definitely need to build a workbench. I'm actually doing this in my parent's garage because mine is small and my torn apart Jeep is taking up all the room. I've entertained the idea of building a small work area overhead of where the welder will sit on the cart, but I will decide on that later.

Thanks for the tips everyone, definitely helps me. I know I'll have gravity against me trying to weld 2x6 rockers in on a non-lifted Jeep, underneath! :blink:

Deff. Friend once told me, if you can weld the upperside of rusty exhaust under a vehicle using a mirror to look through then you can weld anything. Lol i've done it before and its hard...