DIY Welding Project: Cordless Tool Charge Station [Guide]

STEP ONE:

Decide how many tools you want your organizer to hold, and then determine the width of your charger shelf and tool holder shelf. I used three aluminum pieces to make a tool shelf, a charger shelf and a connecting back piece to be mounted to the wall. I wanted my shelf to hold six tools, so I made my charger shelf 23" long and added extra length on each end of my tool shelf so I could bend the sides up.

STEP TWO:

• Cut the 23" tool holder shelf with two 10" sides added to the dimensions (final cut is 8 ½” x 43”) or cut the sides to add separately.
• Cut the sides of the tool holder shelf at an angle — 5 ½" in on the front edge to the back corner of the 10" side.
• Cut the 9" x 23" piece for the charger shelf. Last, cut the 10" x 23" back piece that the two shelves will be welded to.

STEP THREE:

Determine the distance you want between your tools and the dimensions for each tool slot, and then punch or drill holes that you then cut into slots in the tool holder shelf. I used 2" between tools and made all of my slots 1 ¾" wide by 4 ½" to the end of the hole.

STEP FOUR:

Using the brake, bend the sides of the tool holder shelf and the front ½" lip on the charger shelf.

STEP FIVE:

Remove the protective film from the aluminum pieces, then use a stainless steel wire brush to remove the oxide layer from the area to be welded. This will reduce contamination in the weld. After you’re done wire brushing, use acetone to wipe away any remaining oxide dust on the material.

STEP SIX:

Tack and weld the bottom tool holder shelf to the back piece that will be mounted on the wall. I used the Spoolmate 150 spool gun for tacking since the pieces are quite large and MIG welding with the spool gun makes it easier to hold the pieces in place. After tacking with a spool gun, I TIG welded the bottom tool holder shelf in place.

STEP SEVEN:

• Next, tack weld the top charger shelf in place. Again, I used the spool gun for tack welding followed by TIG welds along the seam.
• The charger shelf is 4" above the bottom tool shelf. The top of the charger shelf’s ½" front lip should be flush with the angled side.

STEP EIGHT:

Now that the tool holder is welded together, decide the position of the power strip, drill a hole for the cord and place or mount the power strip onto the piece. I placed my power strip on the back base of the charger shelf to keep the plugs up and out of the way. Your power strip cord may have to exit the shelf on one of the sides.

STEP NINE:

Mount the tool holder to the wall and place your chargers on the top shelf and the tools in their slots on the holder shelf. Hopefully, this helps tidy up your workspace!

STEP TEN (OPTIONAL):

Add two bottom shelf braces to the shelf for additional stability. To complete, cut filler to appropriate length, leaving it a little long to blend in while welding. Insert filler through bottom hole into top hole. Tack weld into place on both top and bottom.