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Stick Welding A Simple But Sturdy Workbench

07 Jun 2019 | about 6 months ago

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A square particle board and two saw horses don't make a great workbench, I know! I really needed to make myself a proper sturdy one, so in this video you can see how I went about it. The design is super simple but the 50mm square tubing I bought with 3mm thick walls makes this construction pretty solid! As you can see from my ugly welds I am no expert about stick welding or any other welding and the super cheap welder I have probably don't help either (fun fact, don't trust the rod rating on a 40€ machine, it can't weld with 2.5 rods! Too bad I discovered after buyng 200). Anyway, with 2mm rods I was able to get a deep and solid weld! At the end this workbench is pretty heavy and can stand me(90kg) walking on top of it without flexing. It's also a bit high at 1m compared to most workbench I see around, that's just my preference, I like to stand straight. And I almost fogot: the workbench measure 185x80cm.
I think that's all I need to say! Feel free to ask me more information in the comments.

Index of operation and materials:
0:17 Test cut to see if the cut angle is set to 45°
1:10 Beveling edges that receive weld to help with penetration
1:44 Tack welding everything in place, it should help to avoid distortion cause by too much heat from a thick weld
2:30 After all sides are tacked I go over everything with full weld
3:13 Grinding flat to weld legs on top
3:40 Cutting legs
4:10 Welding legs with the help of square magnets and tack welds
4:40 Also checking for squareness before full welds
4:45 Closing corners and rounding with grinder
5:30 Cutting angle bar for the middle shelf
5:42 Two cut offs made for perfect spacers at 40cm from the top
6:04 Cutting feet material from scrap steel
6:33 Rounding corners and edges on the 2x72 belt grinder
6:57 Wire wheel removes rust like nothing else
7:10 Tack welding the feet, no need for full welds here, I think there won't be any stress to this joint
8:11 Cold blueing the frame (I degreased off camera). Turned out to be more of an antiquing than blue but I'm cool with that!
8:23 Spray clear coat all over the frame
9:08 Cutting to size a 2cm thick particle board as base for the top laminated board
9:45 Drilling holes in the frame and tapping for M5 bolts. I used 16 bolts to play it safe
10:20 Screweing the top laminated 2cm thick particle board from the bottom so no fasteners are left visible on the top
10:30 Bottom shelf made of a single 2cm thick particle board, cut to size and corners notched off camera
10:40 Again, I weight 90kg, super happy with how solid it came out!


Thanks a lot for watching, I hope you liked the video!
Suggestions and comments are welcome.
Leave a like and share to anyone who might be interested!

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