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Project: Weld Table

Main Project Photo for Weld Table

A welding table is a good choice for a first project since it will provide the foundation for many of your future welding projects.
The table shown here is 4’ x ‘6’ and 38” high. We built it strong enough to hold an engine block (rated up to 1,000 lbs) and big enough to still have room to work. You may choose to downsize a bit.
The tabletop overhangs the frame by 3” on 3 sides to allow room for clamping. On the grate side the tabletop should be flush with the frame to allow you to get closer to the work when you’re cutting. If you choose to modify the table dimensions, keep those considerations in mind and sketch things out prior to starting.

Download Plans [PDF]

Creation Time: 12 hrs Skill Level: Intermediate Suggested Process: MIG & Plasma

Materials Needed

  • 4’ X 6’ X 3/8” top plate.
  • Sheet 41” x 65” x 1/8” for shelf
  • Three 20’ 2 x 2 x 1/8” pieces of square tubing
  • 4’ x 6’ sheet of 16ga
  • 1” x ¼” x 7 ½” flat bar stock (drawer handle)
  • 11½” x 11½” mesh
  • 1” x ¼” x 10’ flat bar stock to make plasma grate
  • Two ¾” x ¾” x 12” angle iron for
  • plasma grate support
  • Four ¾” x ¾” x 12 ½” angle iron for holding plasma chute in place
  • 2” diameter pipe about 3”
  • ¼” round bar stock for tool holders, torch holders etc.
  • Four 4” x 4 ½” x ¼” plate for mounting wheels
  • (2) Stationary wheels rated at 1000# each.
  • (2) Swivel wheels rated at 1000# each with locks.
  • 16 – 3/8’ x ½” bolts for wheels
  • 1 vise (your choice), and bolts to attach to table

Tools Needed

  • Millermatic DVI2
  • Miller Elite auto darkening helmet
  • Miller 625 plasma cutter
  • Miller circle-cutting guide for the plasma cutter
  • Hobart WeldIt E70S-6 solid steel welding wire (.035)
  • 75/25 Argon/CO2 shielding gas
  • Welding gloves
  • Wire cutters
  • Safety goggles with #5 shade for plasma cutting
  • Clear safety glasses
  • Drill and bits
  • 4” grinder
  • Wire cutters
  • Metal cutting saw
  • Square
  • Tape measure
  • Clamps and vise grips
  • Marker

Click to Enlarge Image
1. Cut the pieces for the frame from three 20’ 2 x 2 x 1/8” pieces of square tubing as follows:
  • Piece 1: 3 – 65” pieces, 1 – 37” piece
  • Piece 2: 4 – 37” pieces, 1 – 65” piece, 2 – 12” pieces
  • Piece 3: 1 – 37” piece, 4 – 27” pieces, 1 – 47” piece
Download Plans [PDF] for details.
2. Debur the pieces. Then, starting with the bottom frame, lay the pieces out on a flat surface and tack weld them together. Do the same with the top frame. You will not finish weld until later.
3. Using a square for reference, tack weld the legs to the bottom frame. Set the top frame on the legs, line them up, and tack weld in place. Check for squareness and then finish weld the entire frame.
4. Determine if you want the swivel lock wheels on the short or the long side. Drill and tap the wheel plates, weld them to the frame and attach the wheels.
5. Grind all the welds on the top surfaces of the top and bottom frame to make sure they’re flat.
6. Cut steel for shelf and notch (2” x 2”) the corners to fit. (The shelf is about ¼” short all the way around to allow room for welding.) Weld the shelf in place using a series of 3” welds.
7. Set the tabletop on the frame and cut to size. Notice the use of the straight edge clamped to the table to help ensure a straight edge.
8. Cut the hole (11½” x 11½”) for the plasma grate.
9. Clamp the top to the frame and weld into place.  
10. Plasma Chute: Cut 16ga sheet into:

  • 3 – 12 ½” X 26 ¾” used for the sides and back of the chute
  • 1 – 12 ½” X 12 ½” used for the bottom of the chute
  • 1 – 12 ½” X 19 ¼” used for front of the chute
  • 1 – 12” X 12 ¼” used for the drawer bottom
  • 2 – 7” X 12 ¼” used for sides of drawer
  • 1 – 7” X 12” used for back of drawer
  • 1 – 8 ¼” X 12 ½” used for front of drawer
11. Using the Miller circle-cutting guide for the plasma cutter, cut a hole for the 3” diameter exhaust pipe and weld it into place.
12. Weld the chute together. Note the use of angle iron to ensure that the sides are square.
13. Align the chute with the hole in the table top, then tack weld the base to the shelf.
14. Cut two 12” pieces of angle iron for support inside the plasma chute and weld into place at a depth that allows the grate and mesh to lay flush with the tabletop.
15. Build a grate by cutting flat bar stock into two 11 ½” and seven 11” pieces and welding together.
16. Cut four 12 ½” pieces of angle iron to fill the small gap between the bottom of the frame and the top of the plasma chute. Weld the chute and angle iron in place.
17. Make a grate hanger out of ¼” rod. Bend the two pieces and weld them underneath the tabletop at a convenient location.
18. If desired, make torch holders and tool hangers out of ¼” rod and weld into place.
19. If desired, weld some scrap pipe underneath the tabletop for bending. We used short pieces of 1½” and 2” pipe. To bend, place an end of the rod material to be bent into an open end of the frame and bend around the pipes.
20. Mount the vise to the tabletop and make two gussets from scrap material and weld them under the vise for extra support.

WARNING Safety is the primary concern on any project. Always use tools and equipment in accordance with the manufacturer's instructions. For Miller products, refer to your Owner's Manual for complete safety precautions and procedures.

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