Aluminium Tool Tidy

[Jigantor]

I started this thread to show what I have made, I do not suggest anyone else follow my work nor do I suggest this is the only way to build a tool tidy.
Experts will find this topic very boring.

Today I started making a tool tidy for my welding table.
My welding bay is all aluminium (floor, bench and fixtures) so it is only natural that I decided to make it out of aluminium 6060.
I purchased some 20 x 20 x 3mm or 3/4 x 3/4 x 1/8" square tubes and some 25 x 25 x 3mm or 1 x 1 x 1/8" square tubes, if you have some off cuts from a job that would work well but my aluminium shop cuts my lengths to exact size and only charges by the weight so I have very few off cuts.

This tool tidy is to organise all the tools used every day like screw drivers, files, ruler, square, pence, scriber, hammer and so on.

Ji

[Jigantor]

With all the smaller tubes bunched in the correct orientation get creative and try to clamp them so they stay true. This took a bit of time but it pays off later.

Ji

[Jigantor]

I then cut some 10 x 10mm or 3/8 x 3/8" square bar and clamped that into position.
These will bind the outside tubes together.

Ji

[Jigantor]

I then welded all the binding square bars around the smaller tubes.
Two problems here to overcome.
The first is there is not much room to work in with all the clamps and
Second all these aluminium tubes and 10mm or 3/8" bars act like a cold dam.
Good luck with the lack of room but the second problem was solved by pre-heating. Without pre-heating I would have had no chance of welding this project.

Ji

[Jigantor]

Once all the binding bars are welded turn the tidy upsidedown and weld all the interface joints up. This will stop the inner tubes falling out.
I just welded them as the next step was to grind the welds level so it rested level on its base plate.

Ji

[crawdaddy]

On the same note,If you cut 2x2 square tube into 2'' sections and weld them to a backer you have a nice wall mounted bar clamp rack.Mike

[Jigantor]

Then I arranged the larger tubes into the correct orientation and welded them to the smaller tubes. I then welded the binders on to hold the whole thing together.

Ji

[Jigantor]

The tidy needs to have a base connected to it. I did buy a lazy susan but it takes 5kgs of force to rotate it so it is no good.
I will probably just silicone a square of cork to the bottom and leave it at that.

Ji

[Jigantor]

The tidy also needs a sand and polish to finish it off, but for all intensive purposes it is finished.

Ji

[Jigantor]

Time for a test fit.
Yep all the stuff that sits on my welding bench and gets used all the time fits perfectly.
The reason I welded all the binders underneath is so the welds can not be seen.
I also want to fold and weld a tray to hold my chalk and small items and that is why I left the reccess. I also left the reccess for sculpture or art.

Pretty pleased with the result.

Ji