DIY Welding Project: Cordless Tool Charge Station [Guide] | MillerWelds

DIY Welding Project: Cordless Tool Charge Station [Guide]

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Create a cordless tool storage and charging station together in one, easy welding project using your multiprocess welder.

SKILL LEVEL: Medium

TIME COMMITMENT: 2.5 hours

Here's what you'll need to get started.

TOOLS AND MATERIALS

Multimatic® 220 AC/DC multiprocess welder (or another TIG machine) with spool gun and TIG torch
Hobart® 1/16" MaxalTig® 4943 or 5356 aluminum wire (or similar filler metal)
.080" thick 5052 aluminum sheet (Options: 3003 aluminum sheet for the charger shelf or steel can also be usedfor the entire project)

Stomp shear (or other cutting tool) 
Bending brake or hand bending tool
Rotex punch or hole saw
Stainless steel wire brush
Acetone
Drill
Step drill bit
 

Optional Equipment/Tools


Marker
Tape measure
Square
Level
Dual flowmeter regulator
 

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

STEP BY STEP

Is it a challenge to find spaces for all your tools in your shop or garage? Follow these instructions to build wall-mounted storage shelves for your cordless tools and chargers so you can get them organized and out of the way!
Welder measuring aluminum metal piece with measuring tape

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.

Operator cutting metal piece with stomp shear in shop

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.
Operator cutting slots into metal piece with hole saw

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.

Operator bending metal piece with bending brake

STEP FOUR:

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

Operator brushing aluminum with stainless steel wire brush

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.

Welder TIG welding aluminum shelf

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.

Welder tack welding aluminum shelf with spool gun

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.
Operator drilling hole in aluminum shelf

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.

Shelf hanging on wall with cordless tools and batteries

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!

Man hanging cordless drill on shelf

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.

About Andy Weyenberg

Andy Weyenberg headshot
Andy Weyenberg began welding at his father’s business a few years before joining the Army. After going to school for Electro-Mechanical, he started working for Miller Electric Mfg. LLC as a technical service rep and training instructor. Andy has built and raced stock cars since he was a teenager — and now builds high-performance street vehicles while also managing the Miller motorsports program.
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