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Alumimiun Welder Trolley

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  • Jigantor
    started a topic Alumimiun Welder Trolley

    Alumimiun Welder Trolley

    At present my TIG welder is on the floor of my welding bay.
    I really need to get it up onto a trolley where I can move it about a bit easier.
    On Friday I picked up my precut order from the local ali dealer ready to start my latest project a welder trolley.

    Ji
    Attached Files

  • Jigantor
    replied
    Time for a test fit.
    The welder fits in nice.
    I will fit some handles to the front so to give something to grab when I need to wheel it out from under my bench.

    Pretty pleased with the result.
    It looks great, works well, is neat and gets my welder off the floor.
    Form and function via fabrication

    Ji
    Attached Files

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  • Jigantor
    replied
    Remove all burrs and round all the corners. Then slip the channels on over the top of the tube frame.
    I made the channel legs long enough so you can not see the screws.

    Ji
    Attached Files

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  • Jigantor
    replied
    The next issue is to fold up some channels to cover the top of the tube frame.
    This should protect it and add to the look of the whole project.
    I bent them a little past 90 degs so they will hold on without fixtures.

    Ji
    Attached Files

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  • Jigantor
    replied
    When the side cover was completely folded I then clamped it and screwed it to the tube frame. Remove all burrs and round all corners.

    Ji
    Attached Files

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  • Jigantor
    replied
    I don't like the skeleton design so I decided to sheet my trolley in using aluminium tread plate.
    Typical fabrication;
    Clamp, mark and fold.

    Ji
    Attached Files

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  • Jigantor
    replied
    Time to see how she looks.
    The trolley looks great and all four casters are sitting on the floor.
    If you only require a minimal trolley, job done.
    You may want to screw a handle to the front.
    My welder just sits under the bench, the only time it will be moved is to check the gas line in the rear.

    Pretty pleased with the result so far, but there is still more I have to do to complete the trolley.

    Ji
    Attached Files

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  • Jigantor
    replied
    I then attached the casters to the lower tube frame.
    My welder only weighs 35kilos or 70 pounds so what I have done here will work fine. If your welder is heavier you should make a complete square tube frame.

    Ji
    Attached Files

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  • Jigantor
    replied
    I then used a cordless drill and some self drilling tech screws to fix the shelves to the tube frame.

    Ji
    Attached Files

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  • Jigantor
    replied
    Don't get attached to your welds because the next step is to grind all the side welds down on the tube frames.

    Ji
    Attached Files

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  • Jigantor
    replied
    Today I TIG welded the shelves.
    The shelves are 1.4mm or less than 1/16" thick ali tread plate.
    To weld this I clamp an ali angle to the inside of the corner. This will act like a heat sink and give a little more time before melt down occurs.

    Tread plate is hard to weld your first time because of the raised diamonds. You start welding on thin material and before long you are welding thicker material then back down to thin.
    You have to work your current adjustment between thicknesses via a foot peddle or hand control.

    Just so those that have never welded thin ali plate before the weld has to be small otherwise you will get melt down, and that is why I have added an image of the bead with a match head for scale.
    Watch out Microfusion my welds are getting smaller.

    Ji
    Attached Files

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  • Jigantor
    replied
    I was invited to use a Miller Syncrowave 250 so I tack welded all the parts together at my workshop and headed off.
    I have used the Syncrowave before but only for steel never ali so the settings may be a little incorrect but it got the job done. I must admit I prefer an inverter machine now as you can fine tune your weld a little better. The reg meter on the gas bottle only had 2 notches of gas left so I think there was not enough sheilding gas because towards the end the puddle just kept oxidising.

    Ji
    Attached Files

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  • monte55
    replied
    When I post pics it seems like I can put 4-5 at a time if the files are not too big.
    I'll admit it is a bit annoying to have only one per post........but no one care what I think....sniff

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  • striker12300
    replied
    Originally posted by lens42 View Post
    This is great and very informative, but does anyone know a way that these sorts of posts can be done with one multi-photo posting? If there a forum rule limiting one photo per posting, that rule should be changed. If there is no such rule, there needs to be some instructions on how to put several photos in one post. I checked the FAQ and and even searched for "posting photos", but got no info later than 2002, which was before the board was redesigned.
    Just a suggestion, but you could try to copy and paste them.

    Leave a comment:


  • LarryO
    replied
    Looking forward to seeing the finished product.

    Leave a comment:

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