Welding bench. What size box section?

[stevemon15]

First off, apologies mods if this is in the wrong section, I wasn't sure where to post it.

I'm going to be making myself a simple welding bench, copying some of the ones I've seen on the internet. Basically it's going to be a box section frame, with bracing as appropriate, bottom shelf, and lengths of 10mm flatbar bolted on for the top, as it's cheaper than a 10mm sheet, and will allow access for clamping. Nothing fancy.

Bench is going to be 1m wide by about 500mm deep and about 800mm high.

I'm building to a budget, so I'm trying to price the materials as cheap as possible, but at the same time, I don't want to under build it. It's not going to hold any great weight or get the crap hammered out of it. I have a much scarred old wooden bench for that. I just want a clean flat place to weld.

So the question is, what's the minimum size box section I should be looking at? I'm thinking of 50x50x3mm should be the bare minimum, but if I can go smaller, then it'll be cheaper.

Any advice would be very much appreciated.

Ta.

 

[super noob]

Depends how often you plan on moving it!

I'm making myself one out of 80x80x3 box so its more stable for big items and a vice as the one I've got is the best part of 40kg

 

[cumbriasteve]

A bench should be designed for what you intend to do on it, if you are basically wanting it as a support for a flat surface to weld on and will not have to endure any great weights or hammering then you could probably get away with 40mm box.

For the small difference in price though I would probably suggest the 50 x 50 box, if I was making one myself that's the minimum I would use.

 

[Richiew]

Used 50x50x3mm for my bench. It is nice and sturdy. Would happily use the same stock again if I built another. I built it the same depth as yours but a bit longer. It's nice to have a bit of weight to a bench. You could, like Steve says, build it lighter but I like benches that don't like to move when I'm working on them. I would rather have it too heavy than too light.

 

[Tinbasherdan]

40x40x3 for the frame of mine and 90x90x6 for the legs with 8mm plate on top. It doesn't go anywhere and I have alsorts on it

 

[waddycall]

I'm currently making two out of 50 x 50 x 3. If you're looking for a flat surface be careful how you put it together. I've got my first one dead flat and square but the second one is giving me nightmares with weld distortion. Shouldn't have had that last pint last night.

 

[stevemon15]

Thanks for the replies lads. It sounds like 50mm minimum is the way to go to be on the safe side. I've priced it up by using an online shop, but I'll give my nearest suppliers a ring tomorrow to see if they can do better on price. I may be lucky and get some offcuts a bit cheaper.

I'm debating on welding some flat plate to the legs and bolting on a set of sturdy braked castors, so I can move it out to accommodate larger items. I'm not sure if this will be sacrificing stability though...

PS: Thanks mods for moving to the appropriate section.

 

[Kent]

For the description you give I should use rsa rather than box on that one 50x 50x 5 should do it but you could go lighter and smaller

 

[cianh91]

Iv a 10x5 bench 40x40x3 frame 4mm top on 6 130mm castors Iv made every type of stuff on it never an issue unless your goin into the likes of .2mm tolerances there's no need to go over board with a bench castors won't affect stability if there fitted square and level to each other and good quality

 

[Mr shiney]

Blimey. Mine is 30x30 box with 3mm top and it has two vices and a mill, 20t press, and all my machining stock on it. It had my Landrover engine on it for awhile as well!!

It's bolted to the wall and has never budged!!

I feel a bit inadequate now!!

 

[Mr shiney]

 

[stevemon15]

Food for thought there thanks again everyone. Mr shiney, 2nd on the agenda is a setup similar like you have there in another corner of the shed. I do have a bench for general pounding on, cobbled together from odd bits of wood I had left after getting a roof on the then newly built shed, but pretty (or level, or square) it ain't.

 

[Kent]

View attachment 78207

How do you cope with the grinder at the back of the bench?

 

[Mr shiney]

How do you cope with the grinder at the back of the bench?

No problem at all. It's easy to get at. That's my baby grinder, I made two more that are 2hp, rip your arm off if it got caught......

 

[daleyd]

No problem at all. It's easy to get at. That's my baby grinder, I made two more that are 2hp, rip your arm off if it got caught......

I could actually see that being quite useful, giving you somewhere to rest your elbows/arms when doing intricate work?

 

[Dunny]

I like the grinder holders..very effective!!

D

 

[123hotchef]

I was thinking that too great place for discs first then grinders ontop might have to steal that idea

 

[Kent]

No problem at all. It's easy to get at. That's my baby grinder, I made two more that are 2hp, rip your arm off if it got caught......

I was thinking lower back with stooping forwards over the bench and seeing or controlling things like getting the angles and rake correct on a drill
Personally I like to stand in close and look sort of down onto the wheel BUT I am not you and you might not even sharpen drills on it

 

[rockweasel]

I like the idea of using flat bar for the top (to save £££)

 

[Mr shiney]

I was thinking lower back with stooping forwards over the bench and seeing or controlling things like getting the angles and rake correct on a drill
Personally I like to stand in close and look sort of down onto the wheel BUT I am not you and you might not even sharpen drills on it

I sharpen drills and make HSS lathe tools on it. I rest my elbows on the bench and get in close (with a grinding mask on!!) and it makes for a nice stable body position.

It's been like that for years so I guess I am used to it!!