I’ve owned a small 120 Volt stick welder for several years.
Periodically, I need to do small welding projects around the shop. It works fine for small jobs like brackets, racks, etc.
That being said, I’ve wanted a welding cart to keep all my welding junk together and make it easier to move around the shop. However, as I’ve said many times, I am cheap.
I have an old filing cabinet that has finally reached the end of its useful life as office equipment. The drawer slides are fixed and the key is lost, but I think it will make a fine welding cart with some modifications.
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Step 1: Design
The first thing I did was come up with a design. I need it to be lower than it is now, with a push handle. The welding unit will be secured to the top with storage in the cart for tools and accessories. On the handle will be a cord keeper for the leads.
Step 2: Build the Base
The lower drawer is still fully functional so I decided to keep it intact, ditto for the wheels. I may change them later, time will tell I suppose.
I measured down 8.5" from the top of the unit. I marked the sides and back and using a cutoff wheel, I removed the excess metal. I left the hinges for the upper drawer intact and attached for a supply drawer. (more on that later)
Inside of the back of the cabinet is a large counterweight. I removed it, as is serves no purpose for this project and it was HEAVY!
I installed two 1/2" x 2" strips to keep the sides uniform.
Step 3: Upper Drawer and Handle
Because the drawer slides are fixed, I had to build the drawer and install it onto the slides. I measured the inside area of the slide arms mounted the drawer box.
I made a drawer face and installed it on the box.It ended up being 15" W x 4" H. This drawer will be used for the chipping hammer, wire brush, spare welding rod, etc. My helmet, gloves and fire blankets will be stored in the large drawer of the unit.
The handle is a arm that I had left over from paint mixer project. It used to be one of the arms on the excercycle. I install a square of plywood inside the back of the cabinet and secured the handle with threes 1/2" EMT pipe conduit clamps.
Step 4: Top
I used several pieces of scrap 2” x 10” pine. I cut them slightly wider than the cabinet base (about 17")
I then used a biscuit cutter to slot the edges of the pieces to glue and secure them with #10 biscuits. I clamped them and allowed them to dry.
I stained the top and allowed it to dry.
Step 5: Finishing Touches
I wiped down the drawers and sprayed them gloss red. I think it looks pretty snappy, if I do say so myself.
All that was left then was to fire it up and run a few beads.
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