DIY Welding Project: Multimatic® 220 AC/DC Organizer | MillerWelds

DIY Welding Project: Multimatic® 220 AC/DC Organizer

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Andy shows how to transform your Multimatic® 220 AC/DC with custom trays and shelves.

 

 

Download Project Plan

 

SKILL LEVEL: Beginner

TIME COMMITMENT: 4–6 hours

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

Tools and Materials

Multimatic 220 AC/DC MIG WelderMiller® Multimatic® 220 AC/DC multiprocess welder
Mild Steel Icon 20 ga. mild steel 24" x 48"
bending pliers iconBending or seaming pliers
handshear iconElectric hand shear
Aviation Tin Pliers Icon
Aviation or tin snips
Hammer Icon
Hammer and dead blow  
vise icon
Vise 
C Clamps Icon
C-clamps 
ruler icon
Rulers for marking 
magnetic square icon
Magnetic squares 

STEP BY STEP

step 1

STEP 1:

Using an electric shear, cut your 20-gauge mild steel to 5 3/8 inches by 24 inches. Straighten with a dead blow hammer if needed.

step 2

STEP 2:

Measure 3 inches, 17 inches and 3 inches from the edges, then cut off the remaining 1-inch piece. This will form the back and two sides. Straighten cut edges with a dead blow hammer if needed.

step 3

STEP 3:

Bend the two 3-inch sides to 90 degrees using a vise and a dead blow hammer.

step 4

STEP 4:

Remove the extra MVP plug and mount from inside the machine.

step 5

STEP 5:

Test fit the bent piece to ensure it clears everything.

step 6

STEP 6:

For 12 trays and a top shelf, you need 5 dividers measuring 3 1/16 inches by 4 7/8 inches.

step 7

STEP 7:

Use an electric or straight-line shear to cut out the dividers.

step 8

STEP 8:

Smooth the cut edges if needed.

step 9

STEP 9:

Measure the back side length between the two sides. Divide by 6 to get the spacing for your dividers. Mark the locations.

step 10

STEP 10:

Secure dividers with a magnetic square and tack weld them in place.

step 11

STEP 11:

Decide on the layout of your shelves. Options include a flat top, angled middle and bottom shelf.

step 12

STEP 12:

Cut the top shelf to 16 15/16 inches by 3 1/8 inches.

step 13

STEP 13:

Trim the two long side corners for radius clearance.

step 14

STEP 14:

Clamp to a table and hammer/form a 1/2-inch, 90-degree bend.

step 14

STEP 15:

Trim the top corners of the dividers at a 45-degree angle, flush with the top tray.

step 15

STEP 16:

Spot tack the top tray to the back side and dividers.

step 17

STEP 17:

Verify the spacing measurements between the dividers.

step 18

STEP 18:

Cut and bend the trays. Middle trays: 2 13/16 inches by 3 3/8 inches with a 5/8-inch, 60-degree bend. Bottom trays: 2 13/16 inches by 3 5/8 inches with a 1 3/4-inch, 60-degree bend.

step 19

STEP 19:

Determine the vertical spacing for the trays. Middle tray: 1 1/4 inches from the top edge of the divider to the top of the 60-degree lip. Bottom tray: 1 3/8 inches from the bottom edge of the dividers.

step 20

STEP 20:

Before welding trays, make a clearance cut on the middle divider to clear the door latch. Use a paper template for accuracy.

step 21

STEP 21:

Spot tack the trays in place, starting with the middle tray, then the bottom one. Adjust the Multimatic® 220 AC/DC to 18-gauge and fine-tune the wire speed to 185.

step 22

STEP 22:

Paint your organizer black to match the interior of your Multimatic® 220 AC/DC or a color of your choice.

step 23

STEP 23:

Load the organizer with all your consumables.

Andy Weyenberg

Andy Weyenberg HeadshotAndy 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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