Making a Welding Table / Workbench – DIY Build

I had a quite a challenge on welding very thin square tubing since they are very easy to blow a hole even on lower amp and voltage settings. So I used a technique by welding the tubing joints “tack welding” or “spot spot welding “all the way through the joints to make a full weld. This can prevent blowing a hole into a very thin square tubing of 1.5mm. Yes I could have purchased a thicker wall tubing but to no avail in the city’s local hardware depots.

Powerhouse flux core gasless MIG welding machine has been really put to the test on this project. Also did a lot of tough steel cutting using the Bosch GCO 220 cut off machine, did a very good job cutting 3″x4″ 1/4″ thick steel flat bar and the 2×3 square tubing as well.

Jump to 08:10 part to see the final product showcase.

– Start by cutting 2×3” square tubing to size.
– Grind a small bevel on the edges. And grind off sharp burrs.
– Our house porch has the only flattest concrete floor surface so I assembled the top part there and tack weld all the way.
– Full weld all the joints by using the “tack tack” or “spot spot” welding technique to prevent blow holes.
– Cut 2×2″ square tubing for center braces and lower leg support.
– Close up view on how to tack weld technique. Or we call the method here in the Philippines “spot spot welding”.
– A 0.25″ inch (1/4 inch) flat bar is used to cover the hole on square tubing on upper section of the table.
– Welding magnet helpers really are very helpful. Can’t do any welding projects without them.
– Cutting 4 pieces flat bar using cut off saw. These will be the footings.
– Rounding off the footing’s edges using an angle grinder.
– Weld down steel footings.
– Turn the table upside-down and tack weld caster wheels.
– De-rust everything by with wire cup brush and flap disc.
– After that massive de-rusting task, wipe down every dirt with a cloth and some lacquer thinner.
– Apply a generous coat of metal priming paint to every exposed metal parts.
– Let the red oxide primer paint dry under the sun.
– Then apply top coat enamel paint in 2 coats.
– I used marine plywood, 1/2″ for the lower shelf and 3/4″ for the table top. Cut into size on the table saw. The unfinished workbench is now serving as the outfeed catch table on the saw.
– Finally, screw down the boards using self-tapping metal screws.

Jump to 08:10 part to see the final product in action.

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