Welding Fixture Bench

[Kent]

Thought some guys might like this so I am doing a step by step on the build of a new Welding fixture bench. Very similar to the American Build pro type.
First step was the plans
Which I seem to have misplaced at present, probably out in the shop

The top plate is 10mm thick laser- cut with 336 off 16mm holes for fixtures at 100mm pitch, around the outside edges I have M10 clearance holes were c/sunk machine screws will pick up lugs.

Size of the top plate is 1500x2500 and yes we hand balled it in and it took four of us all working to the limits of our strength. you can see I have set up the lugs as the first step in fabing the base.

 

[Kent]

Ok driver showed at about 10 ish yesterday so prior to lunch this is as far as I got. Besides I seriously needed a sit down after that lift!
I have a rubbish floor at present and to ensure everything was flat I worked off a load of Kingspan I had covered in then some spare ply on top
In the previous photo you see I have the legs cut and adjustable feet at the bottom and end plates on the tops. The positions will be as marked in chalk. Must have taken the picture about 2 ish because by then I had all the cutting done. As it was full lengths of 5mm wall 50x50 and 80x80 I chopped up were pulled off the waggon with the gas axe first coz they are flipping heavy on your own (the willing helpers had now gone off to do proper jobs).
Here is the detail of the adjustable legs

 

[Kent]

M20 was used with 5mm plate, 5mm was also the top capping plate but the latter I could have left out though I think it adds some beef to things and prevents water build up if the legs are effectively sealed.
Next photo is the 50x50 clamped an set up to the inside of the lugs, just in case I created confusion talking of chopping up with the torch, I really aint so good to get a mm perfect cut so the ends were sawn true and square

seem to have doubled up there on the pics, the big hunk of steel on the floor is a U Beam for another job, I have another outside that I must cut today and a tack of 100x100x 8 rsa to chop up into 130mm lengths. It looks like I is gonna be busy!

 

[Kent]

You getting the idea now? now for the legs

 

[Kent]

by tea time I had them all on so called it a day

 

[Kent]

Today I shall crack on with the lower sections, brace bars and castors. hopefully will get a few more pics up tonight or weekend of that (along with those missing plans)

 

[Kent]

found em

 

[Windy Miller]

Looking good. Gonna be a git to turn it over once it's done!

 

[gordon stephenson]

Thank for sharing, lovely table build, (sitting here glowing GREEN with envy)

 

[eSCHEn]

Thank for sharing, lovely table build, (sitting here glowing GREEN with envy)

X 2

 

[MattH]

Are you really welding on top of a block of foam?

Nice looking bench BTW.

 

[gordon stephenson]

Kent, Are you going to be buying a shed load of those lovely Stronghand clamps etc that fit into the 16mm holes?

 

[Kent]

Kent, Are you going to be buying a shed load of those lovely Stronghand clamps etc that fit into the 16mm holes?

Yep but both the UK suppliers have their boots in buckets of treacle, I might get in from the USA were people actually want your cash. Some I will make myself for specific tasks

 

[Kent]

Just finished welding it up 11am. The lugs just carry heavy tacks but the rest is fully stitched up. The reason I didn't weld the lugs fully is there going to be a pain in the posterior to re-locate if anything don't line up just so.

My plan is unbolt the M10 s/sunk that hold the top on to flip it obviously that way beyond muscle power. Any how here it is just wants a clean up and paint and the castors bolting on the location plates after lunch.

 

[Kent]

Are you really welding on top of a block of foam?

Nice looking bench BTW.

Yep, its pretty much fireproof ( they basically build houses out of it now its not like polystyrene) having tried to burn waste once I can attest to that and there are 4 sheets of ply on top. Lovely and flat it is
You use what you have at hand and its a lot safer than welding direct to a concrete floor, more comfortable height wise and you can never do your best work on the floor. Speaking towards best work I had to do all the welds as you see it upside down, flat, horizontal, v-up (could do with having a few quite hours practice with that again I don't do much MIG now)

 

[eSCHEn]

Lovely table Kent. Am with Gordon for sure - super jealous!

 

[Kent]

Not a hard thing to make really, took longer to work through the drawing / development stage and material ordering. Thinking of putting some storage under the closed side (one side is open for full foot room seated). in fact if I had a decent sheet metal kit here I should be starting putting drawers and cupboards in it right away
Here is what I needed
M10x 40 C/snk machine screws and nuts (for the lugs) 10 off
M8 x30 Bolts with nylock nuts and washers 32 off
150 kg rated swivel castors 8 off
1 full length 80x80x5 SHS
3 full length 50x50x5 SHS
( both above gave substantial off cuts to stock)
M20 nuts 12 off
M20 stud 1 off 1 mtr
Some 5mm plate which I keep anyhow for castor plates and the end caps
2500x1500x 10mm laser cut plate ( plain I got quoted £120 from stockholder cost me £300 cut inc supplied & delivered so I figure well worth not drilling over 300 holes for another £180!)

I have some built in adaptations so I can swap to 5 off rectangular plates that I can off set 200 mm opposites but in the present shop that too big.

The plate being secured by screws can be rolled out flat is damaged or flipped over to double the wear time, before replacement is ever needed though.

Of course Bowland Fabrications Ltd are happy to make them for others

 

[gordon stephenson]

Do you think it will need any braces under the top plate with some jacking bolt arrangement to adjust the top to a perfect level surface?, My small steel topped table needed this method to get a slight dip out of the middle,

 

[Kent]

Do you think it will need any braces under the top plate with some jacking bolt arrangement to adjust the top to a perfect level surface?, My small steel topped table needed this method to get a slight dip out of the middle,

the issue is getting use of all the holes easy. I actually think it wont need it but thought long and hard, if it was for putting dirty great big transmissions etc on yes but I have another bench for that. Remember its 10mm and it can be lifted off and rolled flat again if damaged ( though I think I will roll the bench up to the back of a crane equipped truck rather than do the big lift on manually . I am hoping that the fact its tied in around the edges with M10 C/S that provided I keep them tight I should be ok.

The idea is you weld raised up of the bench so heat transmission to the plate should be negligible to non existant. If it was say a one off quick frame I should only use the bench to tack it up, other than that the frame will sit up on fixtures.

 

[gordon stephenson]

If braces were needed, they could be fitted a couple of inches below the table underside with only the bolts coming up to the table top between the mounting holes, But as you say not tacking to bench and heavy work onto another table.