Files:		Text:	PlayBench.txt
		Photo:	PlayBench.jpg

Description:	Mobile, compact, self contained welding bench / work station.

Dimensions:	24" Long x 18" Wide x 36" High
		Work surface: 1/2" Steel plate

Welding Machine:

		Lincoln AC-225C, a simple 225 Amp AC stick welder, selected
		for its compact physical size and hefty weight, securely
		fastened to act as ballast for the top heavy bench.
		See: "Design & Safety Considerations" below.


"Live" Work Surface:

		The bench was designed with a "live" work surface to 
		minimize setup time. Welding Ground is attached to 
		the underside of the work surface by means of a magnetic
		clamp.  Any item placed on the work surface directly,
		or clamped in the vise, is ready for welding.

		An exceptionally flat surface is required for layout and
		alignment of parts which are then clamped to the work
		surface for welding.  1/2" thick steel plate was used
		for the work surface to minimize localised warping and 
		buckling caused by heat from the welding process and 
		to minimize flexing caused by the operation of the 
		attached vise. 

2x4 Insulators:	The manufacturer advised that care be taken to ensure
		that the metal cabinet of the welding machine not come
		in contact with the welding circuit.  It was thus necessary
		to insulate the "live" work surface of the bench to 
		which Welding Ground is attached from the rest of 
		the frame on which the welding machine sits.  This was
		achieved by using 2"x4" lumber as insulating material.

		Lengths of 2x4 lumber were first fastened to the metal frame.
		Lengths of 3/4" threaded rod were welded to the underside
		of the work surface and the work surface then fastened onto 
		the 2x4 lumber, making the work surface electrically
		insulated from the frame. (See photo.)

Shelving:	1/2" Expanded metal was used for shelving.  

		The upper shelf is supported by 1/2"x1/2" angle iron. 
		The lip formed by the angle iron prevents small items 
		from rolling off the shelf.

		The lower shelf is supported by the 1" sq. tubing of the
		frame itself, with additional square tubing spaced 8"
		apart (underneath and not visible in photo) to support
		the weight of the welding machine TO WHICH THE WELDING
		MACHINE IS FASTENED using U-bolts.

Canister Hang Bars:

		1"x1/8" flat bar welded at a suitable height to engage
		the hook on the Electrode Storage Canisters when the
		canister bottoms rest on the lower shelf.  (See photo.) 

4" Casters:	The less wobbly fixed casters were used on the left 
		side (vise side); lockable swivel casters on the right 
		side (machine side).

		Rubber casters were used both to minimize damage to painted
		surfaces when this bench is rolled onto painted surfaces
		of equipment under repair and to electrically insulate 
		the bench/welder from the equipment under repair
		as per manufacturers advice that the metal cabinet of
		the welding machine not come in contact with the welding 
		circuit.

		Use of rubber casters makes the otherwise stable bench 
		rather "bouncy" when attempting to use a hacksaw on 
		work clamped in the vise, but the primary purpose of 
		the vise is to hold pieces of work for welding, so this 
		is not an issue.  

		For less specialized applications, steel casters might 
		make the bench more stable, provided the floor is flat.  
		Rubber casters, by deforming, tend to compensate for an 
		unlevel floor, thus making the bench exceptionally stable 
		for welding, even on a floor that is not perfectly flat, 
		but not suitable for prolonged periods of hack saw work 
		clamped in the vise, due to the 1/2" to and fro motion of 
		the vise with every stroke of the hacksaw.

Design & Safety Considerations:	

		Sufficient ballast is required to make this bench stable.
		This welding bench was designed for use as an integrated 
		workstation as illustrated in the photo with the welding 
		machine SECURELY FASTENED onto the lower shelf in the 
		position illustrated so serve as ballast. WITHOUT BALLAST, 
		THIS WELDING BENCH IS TOP HEAVY AND HIGHLY PRONE TO TIP 
		OVER WITH A HIGH POTENTIAL TO CAUSE PERSONAL INJURY.  

		Due to its dimensions, this welding bench may not be safe 
		for use with a welding machine that weighs less than the 
		make/model of machine indicated herein unless additional
		dead weight is added to make up for the difference.

		To retain overall balance, care was taken to ensure that 
		the center of gravity along the xy-axis remained as 
		congruent as possible with the center of the "foot print" 
		of the bench.  Observe in the photo and note how the weight 
		of the vise in one corner of the work surface is counter 
		balanced for stability by placing the weight of the welding 
		machine in the diagonally opposite corner on the lower shelf. 

		GIVEN THE MOUNTING LOCATION FOR THE VISE, FAILURE TO 
		SECURELY FASTEN THE WELDING MACHINE TO THE BENCH FRAME 
		IN THE POSITION ILLUSTRATED TO ENSURE THAT IT REMAINS
		FIXED IN THAT POSITION, MAY RESULT IN THE BENCH 
		TIPPING OVER AND CAUSING PERSONAL INJURY. U-bolts were 
		used to securely fasten the welding machine to the shelf 
		supports (not visible in photo) of the bench frame.

History:	As of this writing, this welding bench has been in 
		use for about 3 years and was found to be quite stable 
		and tip resistant.  Compared to larger, more sophisticated
		equipment in the shop, it was nicknamed the "Play Bench" 
		for its compact size and its simple, appliance like 
		utility as a minimalist, back-to-the-basics workstation.



"Speechless"
2005-Aug-26