DIY Project: Welding Cart

DIY Project: Welding Cart

In this video, @Making Stuff walks us through the full process of building an aluminum welding cart, with some thoughtful design improvements. The repositioned side handle is a smart move to prevent interference with the MIG welder's side door, and the optimized gas bottle layout makes switching between multiple welders way more efficient. This cart is simple, practical, and designed with both functionality and safety in mind. It's perfect for organizing your gear and moving equipment around the shop seamlessly. Whether you're a pro or just starting out, this DIY project is definitely worth checking out. Grab your tools and let's get to work!

1. Material

  • 1.5-inch aluminum angle
  • 1.5-inch aluminum tube that is 1/8 inch thick
  • 1/8 inch thick flat plate

2. Equipment

  • YesWelder YWM-211P MIG Welder
  • YesWelder LBT150 Aluminum Welding Spool Gun

YesWelder LBT150 Aluminum Welding Spool Gun

LBT150 150AMP Aluminum Welding Spool Gun

  • YesWelder Welding Helmet

LYG-Q800D-YM Larry Customize Monster Graphic Auto-Darkening Welding Helmet

LYG-Q800D-YM Larry Customize Monster Graphic Auto-Darkening Welding Helmet

  • Mitering chop saw
  • 4.5 inch angle grinder
  • Welding clamps
  • Minion squares
  • 7.25-inch circular saw
  • Jig saw
  • Cordless drill
  • Cordless drill with a 1.5-inch hole saw
  • Surface conditioning tool

3. Building Process

3.1 Material Preparation (1:34)

  • Choose aluminum (use scrap aluminum), cut the bottom aluminum sheet, and grind the edges to ensure smoothness. PS: You can also use the materials you already have.

Material Preparation

3.2. Making the bottom frame for the welding cart. (2:31)

Making the bottom frame for the welding cart.

3.3. Building vertical supports and top frames. (5:01)

Building vertical supports and top frames.

3.4. Prepare and cut the aluminum shelves for the welding cart. (6:49)

Prepare and cut the aluminum shelves for the welding cart.

3.5 Cut and prepare the pipe handle, use a homemade notch fixture to process the pipe, ensuring a flush contact surface. (8:46)

Cut and prepare the pipe handle

3.6 Install and weld the pipe handle. (11:58)

Install and weld the pipe handle.

3.7 Surface Treatment (12:33)

  • Perform a brushed finish on the aluminum surface to prevent scratches and maintain the material’s characteristics.

Surface Treatment

3.8 Assemble the parts and secure them with welding. (12:55)

  • Secure the upper welder mounting plate and lower storage shelf.

Assemble the parts and secure them with welding.

3.9 Installing four wheels. (13:39）

Installing four wheels.

3.10 Safety Testing (14:13)

  • Check structural stability and ensure weight capacity (referencing the 200 lbs limit).

Safety Testing

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Thank you for the DIY project. You can follow his YouTube channel @Making Stuff here.

 

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