Name:
Date:
Beginning Metal Repair
Rolling Cart
Objective:
Learn a practical application of welding by building a rolling cart
Provided Material:
1. Steel flat stock – 3” X 1/8”
2. Steel bar stock – 1” X 1/8”
3. Steel angle – 1 1/2" X 1 1/2" X 1/8”
4. 4 – wheels
5. The students will provide fasteners for two wheels.
Instructions:
Trapezoid
1. Cut 12 – 4” long practice pieces from the steel flat stock. Use these pieces to practice
grinding and welding.
Thetopandbottomofthecartareeachcreatedoutof4trapezoids.Thetrapezoidsare
madefrom11/2"X11/2"X1/8”steelangle.Thetrapezoidsarecutat45°angles.Thetop
andbottomareeachasquare.Thesquaresarecreatedbywelding4trapezoidelements
together.Toinsureproperwelding,cuttinganglesandsizemustbeveryprecise.(“Measure
twiceandcutonce”)Itmaybenecessarytogrindthesegmentstoinsuretheyareallexactly
thesamelengthandangles.Whenwelding,insuretheanglescreateasquare.
2. Create 4 practice trapezoids out of the steel angle. The long side of the trapezoids should
be 4”. Test fit the pieces to insure a proper fit. Grinding maybe used to adjust fit. Practice
tack welding the trapezoids into a square.
3. Create 8 top/bottom trapezoid elements. The long side of the trapezoids should be 30”.
Test fit the pieces to insure a proper fit. Grinding maybe used to adjust fit.
4. Create a top and bottom square by tack welding the 30” trapezoids together. Weld only
on the outside of the joints since the vertical elements must still be added.
5. Using the 1 1/2" X 1 1/2" X 1/8” steel angle, create 4 vertical elements. The vertical
elements shall be straight cut at 90° and 24” long. All four vertical elements should be the
same size, so cut carefully. It maybe necessary to grind the elements to insure they are all
exactly the same length.
6. Create a box by adding the vertical elements to the top and bottom. The edges of the
vertical elements may need grinding to insure a tight fit in the corners. Test fit everything
and then tack weld.
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7. Complete the welding on your practice square.
8. Insure everything is square. Weld up all the joints, both inside and outside. Be careful not
to add too much extra metal on the top and bottom surfaces. These surfaces will be
ground flat.
9. Using the 1” X 1/8” bar stock, create 4 corner supports. The supports should be trapezoid
in shape, 45° angles at each end and 8” on the longest side.
10. Weld the 8” corner supports to the underside of the topside.
11. Using the 1” X 1/8” bar stock, create 8 corner supports. The supports should be trapezoid
in shape, 45° angles at each end and 6” on the longest side.
12. Weld the 6” corner supports between the vertical elements and the joints on the top.
13. Weld the 6” corner supports between the vertical elements and the joints on the bottom.
14. Grind the top and bottom flat.
15. Two wheels will be rosette welded to the bottom. Determine the size of the corner
support used to support the wheels and joints. The wheels should be placed as close to the
edge of the structure as possible. Mockup the corner support with paper. Once your
instructor has approved your paper design, create the corner supports and weld them in.
Rosette weld on the wheels.
16. Two wheels will be bolted to the bottom. Determine the size of the corner support used to
support the wheels and joints. Insure there is enough space to clear the washers and no
bolts are mounted on a welded seam. Mockup the corner support with paper. Once your
instructor has approved your paper design, create the corner supports and weld them in.
17. Determine the bolts and washers need to attached the two wheels. Purchase the hardware
and attach the wheels.
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