Opportunity is missed by most people because it is dressed in overalls and looks like work.
Thomas Edison

Let’s get our hands dirty. We were looking for a workbench fitting our workshop as well as possible. Buying a workbench wasn’t an option since we want to broaden our skills constantly – and for us welding was breaking new ground. While mainly focusing on electronic projects we knew that we were always running out of desk space – you all know what I’m talking about. So, the main goal was to prevent things from falling off the table. As for the shape we decided to go with a stand-alone workbench, accessible from both sides. Preparing for even heavier tasks, mild steel is the table frame material to go for.

1. Cutting steel
Cutting 2mm thick mild steel (S235JR) is an easy task but it will take some time to get the right results. An angle grinder and a 1mm cutting disk will do the job. Just mark the tube, clamp it with a screw clamp and cut each side separately. Get rid of any sharp edges.

2. Alignment
To align the tubes properly some magnetic welding holders will do magic. If your cuts are not precise enough (e.g. edge joints) just use some screw clamps to freeze your alignment. When the welding-arc heat is applied, a strong and solid fixation prevents bending of the tubes.

3. Welding
Before the welding begins a cleaned surface of the steel tubes is important. To do so just use the angle grinder with a fresh sanding disk. When done, start to tack the edges of your joints without filler rod. If the gaps of your joints are too big use just a bit of the filler rod. After a little cooling time start to weld each joint properly.

4. Post work
When all welds are cooled down, flatten your welds by using the angle grinder (sanding disk) one more time. 6mm holes for screwing the wooden table top will work.

5. Where do I get help?
The diy guide of mig-welding.co.uk is a really nice and lightweight source to start and to find the right settings for your TIG or MIG welding machine. Furthermore have a look at the Youtube channel of weldingtipsandtricks – Jody is the man when it comes to any kind of question around the topic of welding. If you need more help or want to know more about the workbench just drop us a line.

TO-BUY-LIST

– Metal, 40x40x2 mm steel square tube
– Tabletop, wood, at least 3cm thick
– Garage or empty space
– TIG or MIG welding machine including appropriate gas
– SG2 filler rod 1.6mm
– Welding helmet, Leather gloves
– Angle grinder, 1mm cutting disk, sanding disks
– Magnetic welding holders, 2 or more
– 2 or more screw clamps
– Powerful drill, 6mm drill bit