DIY Welding Project: TIG Rod Storage Rack | MillerWelds

DIY Welding Project: TIG Rod Storage Rack [Guide]

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Follow these instructions to build a storage rack to keep all your TIG filler metal clean and organized.
DOWNLOAD PROJECT PLAN

SKILL LEVEL: Beginner

TIME COMMITMENT: 3–4 hours

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

TOOLS AND MATERIALS

.063 3003 alloy aluminum
1" PVC pipes cut to 36" length (12) and end caps (24)
Multimatic® 220 AC/DC multiprocess welder
1/16" 4043 filler metal

Stomp shear, band saw or reciprocating saw

Hole punch or hole saw & 1/8" drill bit  

Drill or drill press 

Sheetmetal brake or bending tools 
 

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

STEP BY STEP

Operator cutting sheet metal with a stomp shear in a shop

STEP ONE:

Cut your top piece to 5-1/2" x 29", or whatever measurements work for your workbench. My Miller ArcStation is 29" deep so I cut the bottom piece to 4" x 29".

Fabricator making marks on metal piece along ruler

STEP TWO:

Starting with your top piece, center 12 holes for the PVC pipe 1-5/8" from the long edge. Then, starting 3-1/2" from the short end, mark a hole every 2". The 12th hole should land at 25-1/2". 

Welder marking measurement on sheet metal

STEP THREE:

Do the same on the bottom piece, but holes should be 2-1/8" from the long edge.

Welder tracing circle outline onto metal piece

STEP FOUR:

Because I’m using a Rotex punch to make my hole instead of a standard hole saw, I made a 1-3/8" circular template and centered the template around each mark to outline the outside PVC diameter. Punch out the holes.

Operator bending piece of sheet metal

STEP FIVE:

Taking the top piece, create two 1", 90-degree bends on the front side and a 1/2", 90-degree bend on the back edge.

Operator bending piece of sheet metal

STEP SIX:

The bottom piece will get a 1/2", 90-degree bend on the front and a 1", 90-degree bend on the back.

Operator drilling small holes in metal piece

STEP SEVEN:

In front of each large hole, drill two 1/8" holes through the top and 1" bend underneath, approximately 1/2" from the edge.

Metal pieces with marked measurements sitting on work bench

STEP EIGHT:

Create two gusset-style sides for the top. Start with two 4-1/2" x 4” pieces. You’ll need to create a 1-1/2" bend on your 4” side; but first, cut 1/2" x 1-1/2" off the top of the side. Then on the other topside corner, measure down 1” from the top and cut the bottom corner off between the 1" mark and the 1-1/2" mark for the bend. You’ll do the same on the other piece, just mirrored.

Close-up of welder TIG welding pieces together

STEP NINE:

TIG weld gusset sides to your top rack.

Operator holding metal gusset

STEP TEN:

For the bottom gussets, you’ll need two 3" x 4" pieces with a 1-1/2" 90-degree bend on the 3" side. Weld to the top of the bottom rack.

Operator cutting PVC pipes in shop

STEP ELEVEN:

Cut your PVC pipes to between 35" and 35-1/4" long. Clean and deburr the ends.

Split image of rack being bolted to workbench and PVC pipes being hammered into place

STEP TWELVE:

Mount the rack to your weld bench. Leave just enough room beneath the bottom piece to slide the PVC caps under. Use a rubber hammer to seat the PVC pipes tight into the bottom caps.

On top caps, sand the inside to make them slip on and off easier. Drilling a small hole on top also helps eliminate a vacuum inside tubes.

STEP THIRTEEN:

On top caps, sand the inside to make them slip on and off easier.  Drilling a small hole on top also helps.

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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