This is my first Instructable and its on how to fully build a steel coffee table and ideas for a custom design finish in the center. It includes welding, angle-grinding and filing to do this project. I powder coated my table and am waiting for it to be returned from the shop but i included instructions for painting at home. Feel free to comment for any questions and enjoy building!

(NOTE: I REFER TO MOST PHOTOS WITH NOTES ON THEM TO EXPLAIN INSTRUCTIONS. LOOK OUT FOR ALL PHOTOS)

Step 1: MATERIALS LIST

LEGS (4)Light MS Pipe: 450x40
LONG RAILS (2)Light MS Pipe: 800x25
SHORT RAILS (2)Light MS Pipe: 400x25
TOP SHORT RAIL (2)Flat MS: 500x50x8
TOP LONG RAIL (2)Flat MS: 900x50x8
GLASS TOP (1)Glass-Clear: 810x50x6
RUBBER GLASS PADS (4)
CUSTOM DESIGN: (OPTIONAL)
SPRAY PAINT & PRIMER

Step 2: TOOLS LIST

HAND TOOLS

Bastard File
Round File
Rule
Marker (I used an ARTLINE 70 1.5mm PERMANENT MARKER)
liquid white out
Tri-Square

ELECTRIC TOOLS

Angle Grinder
- 100mm Flap disk
- 100mm Grinding disk
MIG Welder (With appropriate tool set-up)

EQUIPMENT

4x large G-clamps
4x right angle industrial magnets

Step 3: GEAR UP!

It is recommended to wear;

Leather/ Protected shoes
Apron
Safety Goggles

Though-out the whole project.

During welding, the following PPE should be worn:

Leather Apron/Jacket
Leather shoes
Leather Gloves
Welding Helmet

Step 4: 1: PREPARING TABLE TOP FOR WELDS

LONG BAR:

Measure 50mm from top of bar and use a Tri-Square to mark end of line. use Liquid Correction Pen to highlight edge for filing, these are your mating edges for welding. Repeat on opposite side.

Refer to image

LONG BAR and SHORT BAR:

Use a Bastard File to form a bevel on both sides bar that have been marked out, forming a point.

Refer to image

Step 5: 2: WELDING TABLE TOP

Place all 4 flat bars on welding table with all mating edges trouching. Use G-Clamps to clamp to table and check squareness with Tri-Square. Tack weld corners by going to opposite sides after every tack for 8 tacks.

Repeat on opposite side.

Fillet Weld over tacks to form strong joints, in the same pattern, but only 1-4. repeat on opposite side.

Step 6: 3: PREPARING LEGS AND WELDING

After the 6 pipes have been cut to length (2x short rail, 2x legs), use a round file to remove arras edges from cutting points.

(note: REMEMBER TO DO THESE STEPS TWICE FOR BOTH SETS OF LEGS)

use a rule to mark a straight line in liquid white out from one end to the other

Use a grinding disk to form an indent into the two sides of the short rail, so it can fit snug over the leg pipe, do this using line as a middle point to have some-what identical grinds.

line up pipes to favourited height, mine were 100mm from top. i also used a provided jig, but G-clamps work if you spend time lining it up and using tri-square to check right angles.

Tack weld in 2 spots according to photo.

check squarness again with tri-square

fillet weld around, breaking in 4 sections

(REFER TO IMAGES)

Step 7: 4: GRINDING AND FILING

Place pieces in a vice and using an angle grinder grind and flap disk over welds to makes flat on both sides of table top and minimized on legs.

Files edges to form flat surface

Step 8: 5: FINAL WELDS AND ASSEMBLY

make custom spacers to elavate log rail to legs. mine were 100mm tall, the same height as the short rail were elevated.

use right-angle magnets to hold together

check every piece is equally adjusted to the mm

tack opposite sides of each piece again in a pattern

4 tacks to each leg pipe connected to table top

2 tacks to each end on long rail

check squareness again

fillet weld around all tacks

Step 9: 6: GRINDING AND FURNISHING

angle-grind the new welds and file and cold chisel away debris.

use sandpaper wrapped over a file and sand away paint on table top

use spray-paint primer over whole table

If you plan to use a brush to paint your metal with epoxy enamel, stir the paint properly and pour it into another container. This will make sure the paint doesn’t dry on the lip of the tin of paint. Avoid putting too much paint on your brush or it will run or drip on the floor.

Make sure your finished product looks the best it can by applying a second coat. Always read the instructions on tin to find out how long to leave the first coat to dry, before you can apply the second coat.

Step 10: FINISHED PROJECT OR ADD CUSTOM DESIGN TO CENTER OF TABLE

project is now finished,

you can add a custom design to the middle of your table easily, just plan it and make it! I have included some photos of similar tables and their custom designs for inspiration

this is my first Instructable so i hope it is good and it worked out for you.

comment any questions and i will get back to you.