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DIY Welding Project: Metal Wagon [Guide]

Tom Patsis

DIY Welding Project: Metal Wagon

DIY Welding Project: Metal Wagon

Build a durable custom metal wagon with this advanced DIY welding project. Follow step-by-step instructions to fabricate an aluminum wagon with a welded frame, steering assembly and rugged running gear for years of dependable use.

Metal Wagon Project Plans

Tools and Materials


  • Millermatic® 211 (or other MIG welder)
  • Dynasty® 280DX (or other TIG welder)
  • 1/16" MaxalTig® 4043 aluminum wire (or similar filler metal)
  • Pneumatic sheet metal shears (or other cutting tool)
  • Stomp shear
  • Slip roller
  • Sheet metal brake
  • Band saw
  • Chop saw
  • Drill press
  • Belt sander
  • Lathe
  • Hand file
  • Clamps
  • Tape measure
  • Hand tools for the fasteners
  • Four shifter kart wheels and slick tires (metric or American bolt pattern)
  • Four dual bearing wheel hubs (matching bolt pattern for wheels)
  • 4043 aluminum tubing (1" × .065" × 6')
  • Box tubing (1" × .065" × 15')
  • .065" thick 4043 aluminum sheet (4' × 8')
  • 1/4" thick steel plate (12" × 12")
  • Steel tubing 1 (3/4" × .125") and 1 (7/8" × .065")
  • Aluminum strapping (1" × 1/4")
  • 5/8" fine thread bolts, 4 (6" with lock nuts)
  • Delrin plastic (1-1/4" × 3.5")
  • Bar stock plate (3/4" × 12")
  • Misc. nuts and bolts
  • Optional: Magnets
  • Optional: Poster board
  • Optional: Marker
  • Optional: Scissors

 

WARNING: READ AND FOLLOW ALL LABELS AND THE OWNER’S MANUAL.

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Tom Patsis Author Card

Tom Patsis is a metal artist and owner of Cold Hard Art. After studying automotive technologies in high school and earning his degree in automotive, high performance and alternative fuels at the University of Northwestern Ohio, Tom moved to Indianapolis to work for Don Schumacher Racing. He spent six years with the Pro Stock team before he switched to working in the fabrication shop. It was there that he got started with metal art — later opening up his own shop to use as an outlet for his creativity. Follow Tom on Instagram @ColdHardArt.

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Posted May 12, 2024