Aluminum Welder CartAuthor: Dave Date: 12.09.12 - 4:55am I have wanted to be able to weld aluminum for about 20yrs now, so I finally decided to splurge and buy a Tig welder so I could learn a new skill. After comparing all the models I ended up going with the Hobart Ez-Tig. From what i understand it is basically the same as the Miller diversion 165 but with a cheaper torch. On the up side, it came with a foot pedal, which is a 140 dollar add on for the diversion which only comes with a thumb knob. Overall I am quite happy with teh machine, it runs and welds fine. I have had a hobart handler 140 for over a a decade that i am very happy with. Anyway, the first project for a new welder, is of course a new cart. Since it can do aluminum, i figured it was the perfect chance to get some aluminum welding experience. Not really being to sure of aluminum weld characteristics (or the quality i could produce on my first project), i came up with a design that would place as little strain on the welds as possible. I ended up using 25ft of 1in x 1/8in angle and around 12 hrs labor. Final cost was 90 dollars (50 for the aluminum, 40 for the casters) 
The supports for the top tray are two pieces of angle welded together to form a square tube. One piece is longer so that it cradles the corner, and so the tray can rest securely on the shorter inside piece (no stress on the welds). The tank support was done out of steel and bolted on, because a high pressure tank is not something i want to take any risks tipping over. The nice bends in the steel are because the pieces were taken from an old exercise bike :) The back wheels are on their own lengths of angle to widen the stance and bolted to the main frame. No welds on these pieces means nothing that can break, and not compromising the temper of the aluminum angle. The wheels are also directly under the tank which means as little as stress as possible is transmitted to the main frame and welds. Originally i had 5" casters on it with no extensions. It was to easy to tip and i wasnt happy with it. So the smaller wheels mean lower center of gravity and farther out is more stability. One thing not obvious is that larger casters have a larger eccentricity as they revolve around the center balance point. So they greatly reduce the effective center balance point of the platform when at their minimus. One more thing to mention before I finish with the casters. My old welder cart had rotating casters on the front, and two large wheels on solid axels on the back. That design has good stability, but the turning radius and maneuverability is shit. Since finishing this cart, I ended up switching my other welders cart over to this wheel design as well. Much better. The caps that go over the wheel extensions are not structural, they are just 2 pieces of thin guage square with their bottoms cut out on a table saw, and a plate welded on top. They are a snap fit over the caster bolts, just squeeze the side walls together a bit until they snap on. It was just a nice aesthetic touch to hide the angle iron projecting out. Anyway, more picts. AL welding isnt that bad when you have the right equipment and you properly clean the metal before you begin. One small trick I learned when joining two pieces. If you leave one piece a touch longer than the other, you can use the excess as a built in supply of filler rod so you dont have to add any and then melt down even. Frees up your second hand to help steady the torch. Another cool thing about aluminum is that you can cut it on your table saw with a carbide blade to get perfect miters and cuts. Aluminum welding is also more challenging and fun than steel. Actually just tig welding is more fun than mig. There is no smoke to obscure the weld puddle, and you can move at your own pace since you control the addition of metal and the amount of heat going into the work. Its takes that welding zen to the next level! 
Comments: (3)On 12.23.12 - 7:17am Dave wrote:
On 12.28.12 - 1:19am Dave wrote:
On 12.28.12 - 4:05am Dave wrote:
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