Alumimiun Welder Trolley

[lens42]

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.

[LarryO]

Looking forward to seeing the finished product.

[striker12300]

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.

[monte55]

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

[Jigantor]

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

[Jigantor]

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

[Jigantor]

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

Ji

[Jigantor]

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

Ji

[Jigantor]

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

[Jigantor]

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