The fun part or so I thought! (If you missed the first or Second installment click on them.) This was the first project I had taken on where I needed to weld. So I bought a second hand arc welder for 50 dollars they are around $130-150 new you also need a mask(not pictured), gloves (longer than those pictured!), chipping hammer, and steel brush also if you are starting out like me an old chisel will come in handy to dig out the slag, don't use a good chisel!
So with welding there are 3 main types ARC, MIG and TIG. TIG is probably the most difficult and most expensive but it does give great welds on a variety of metals, MIG is probably easiest and good for thinner metals but about 3 times more expensive than ARC. ARC has been around forever (just look at mine hardly state of the art!) is the cheapest and can weld a variety of thicknesses of mild steel but takes LOTS of practice to get good at.
.In order to ARC weld you need to strike an arc and then SLOWLY go round in small concentric circles over the area you need to weld. I had to teach myself and the penalty for failure is grinding the weld down and starting again. Let me tell you I am sick of grinding! Try to keep the weld horizontal, make sure the 2 pieces of metal, making the join, butt up close together and take your time with slow deliberate movements when welding. I used 2.5mm 6013 electrodes and they worked fine for me.
It took me a long time and lots of practice to get acceptable welds so keep persevering with it and remember once you can weld its a valuable skill you will have for life!
As I was completing the frame I made a few slight changes. I put a crossbar in so the vice can bolt directly onto the frame I will have to drill 2 holes for the bolts but that should be pretty simple.
I deliberately welded each leg half on length brace and the other half on the width brace to give the table greatest strength. The bottom left corner of the above photo shows this point.
I also decided to strengthen the middle of the table by adding a leg and brace to all 3 longitudinal beams on the bench frame. This really strengthens the frame if you decide to do this make sure to make the middle leg a few mm shorter than the others to avoid frame rocking.
Once the frame was complete. I then needed some way to attach the wooden top to the frame. I decided on rectangular pieces of 3mm steel which I drilled a hole in and then welded to the table in each corner and the middle front and back.
Finally the frame is nearing completion but what to coat it with? Its already had a galvanised coating to protect the steel from the elements but this looks pretty agricultural. After hunting around for different solutions I came across engine enamel spray paint.
This stuff is fantastic super tough wearing, resistant to heat, oil, grease, etc. Just the ticket to spruce up the frame.
Here is the completed frame.
After using this design for almost a year I can report that it has held up really well. Were I to build it again I don't think there is anything I would change. If the area where it was being housed was made of concrete instead of pavers I would dynabolt it too the ground. As sometimes with the grinder going, the table vibrates a bit.
I hope this post helps out other DIY enthusiasts. You might be interested in these DIY energy ideas
You can also see my review and update of additional features here