For a hobby welder using less than 240 amps and less than 50 ft in combined cable length, a 1 gauge welding lead is sufficient. If you exceed these constraints or are doing more advanced welding, read through this guide to find a welding cable size that suits your needs.

A welding lead or cable is an all-important part of your welding setup. It is the object that connects your welding machine to your electrode, making sure that you actually have the power you need to weld. Without your welding leads, you would try turning on your welder, and only dust would come out, not a spark.

Choosing the right size welding leads is important for your safety and the effectiveness of the machine you are working with. A few factors influence the size of welding leads you need, including amperage, duty cycle, and other things. When in doubt, consult a sizing chart.

Here is your guide to choosing the right welding leads for your set-up.

What Is a Welding Cable?

Before we talk about the size of the welding cable you need, we should probably establish what a welding cable is in the first place.

Welding cables and leads are the same things. They are important parts of your arc welding setup. Welding leads are copper wires that connect the arc welding machine with your electrodes. They deliver the electrical power from your machine to the electrode, starting the arc. 

Welding cables are specially designed to handle large quantities of electricity. Almost all of them contain copper, one of the best electrical conductors. However, different sizes of welding cables are designed for different electrical capacities. Get a too small cable that might burn or cause an incident when you try to surge a high amperage through it. That’s why choosing the right size welding cable is important.

Types of Welding Cables

There are a few types of welding cables you will encounter when you head to the shop to pick some out. You can distinguish them according to a few of the following factors.

1. Core Material

The core of a welding cable is a strand of hundreds of thin wires that are very flexible and conduct electricity. Most welding cables use a copper core because this metal is the best conductor of electricity. Some use aluminum because it is lighter and more affordable, but the diameter has to be larger to fit more strands of wire.

2. Insulation Material

Welding cables also differ in terms of the material used to insulate them. EPDM and neoprene are two types of synthetic rubbers that are popular insulators because they are very flexible. PVC is less flexible but tougher and less likely to tear even when exposed to rough environments.

3. Purpose

Finally, the welding cables you see in stores differ depending on their purposes. Most are designed to connect the arc welding machine with the electrodes. However, some welding cables are actually grounding cables designed to prevent electric shock. Make sure you get the right type of welding cable for your purpose.

AWG Welding Sizes

AWG or American Wire Guide describes the size of welding cables. You will often see welding cable sizes in terms of their AWG Guage, which has the following specifications:

Welding Cable Size Chart

This table shows the recommended welding cable size in AWG for different lengths (electrode and work cable combined) for different current draws:

What Size Welding Leads Do I Need for a Duty Cycle Welder?

Every single welding machine has a duty cycle. The duty cycle describes how long the welding machine can be operational in 10 minutes without overheating. The duty cycle changes with a few factors, including the amperage of the welding machine.

As a rule of thumb, the longer the duty cycle, the thicker welding leads you will need. If the duty cycle is longer, more power will be coursing through the welding cable. You need a welding cable that will stand up to that consistent amperage. 

For a higher duty cycle (this will depend on your machine and the type of welding you are doing), choose a thicker welding lead, such as 2/0 or 3/0 cable size.

What Size Welding Leads Do I Need for an Amperage Welder?

Every welding machine also has its own amperage. The amperage of the welder machine describes how much current flows through the circuit. Most welders can adjust amperages along a range. 

If you know that you will be working on projects along the higher end of the range of your welder’s amperage, you need to get bigger welding leads with a higher ampacity. The ampacity is the current that a cable can carry without causing damage. 

The biggest potential damage comes from the heat that electricity generates. If your cable has a low ampacity, the electrical current will burn through the cable. At best, you will need to stop work and replace your cables. At worst, you will cause a workshop fire.

Calculating ampacity on your own is difficult because you have to look at the size, circuit length, and other factors. That is why you should look at the cable size chart. These charts tell you which cable you should get based on the maximum amperage and duty cycle. They are very useful tools to have when you’re buying welding cables.

What Length Welding Leads Do I Need?

Your welding leads should be long enough to reach your workspace from the welding machine. I recommend selecting at least 15 feet of welding lead length to give yourself plenty of room to maneuver.

However, the length of the welding leads also impacts the current capacity.

When choosing your welding cables, look at the length of the welding setup, from your grounding cable to the electrode holder. Then, look at the chart to see the cable size you will need. Choose the length of the welding leads that will fit within the range recommended for your cable size.

For example, if you are operating at a 20% duty cycle and want to use a size eight cable, you must ensure the setup is below 50 feet. You will need a shorter welding lead than if you go a size up and choose a size four welding cable.

Final Thoughts

Choosing the right size welding cables is important because you don’t want your machine to work improperly or catch fire. Luckily, a standardized size chart using American wire gauge sizing tells you which size to get according to duty cycle, amperage, and length.

The post What Size Welding Leads Do I Need? [Welding Cable Chart] appeared first on Beginner Welding Guide.

Oxy acetylene tanks, including torches, are an important fuel source for welding machines. These tanks include oxygen and acetylene, a very hot fuel gas. The tanks contain two important gases that combine to create a hot fuel. Having enough oxy acetylene on hand ensures you can get the job done.

You should get the right size oxy acetylene tank to have enough fuel. Choosing the right tank can be overwhelming when you look at the range of sizes available. Think about the amount of gas you plan to use for your project and the space you have to store these volatile tanks.

Here is your complete guide to different sizes of oxy acetylene tanks.

What Size of Oxy Acetylene Tanks Are Available?

The sizing charts of oxy acetylene tanks differ from country to country. There are even different sizing conventions for the United States and Canada. 

There are ten different oxy acetylene tank sizes available in the United States. In order of increasing height, they are:

The shortest tank, according to the United States size chart, is the MC tank. This tank is 13.2 inches high and has a maximum capacity of 10 cubic feet of gas.

The largest tank is the 5 tank. This tank is 51 inches high and has a maximum capacity of 350 cubic feet of gas. Unless you are purchasing oxy acetylene tanks for a massive workshop or factory that relies on this gas to fuel welding torches, you will probably never need this much oxy acetylene. 

Just because a tank is the tallest or widest does not mean it has the biggest capacity. The tank with the biggest capacity is the WTL cylinder, which contains 390 cubic feet. Before buying a tank, you should carefully look at the dimensions and match them to the demands of your project. It’s not as simple as assuming that the tallest or widest will have the greatest gas capacity or necessarily be the best for you.

How Heavy Is an Oxy Acetylene Tank?

Besides the height and gas capacity, another important dimension to consider for the tank you are getting is the weight. 

How heavy an oxy acetylene tank is will depend on the size tank we are talking about. For example, the smallest tank will only weigh about 7 pounds. Meanwhile, the 5 tank weighs about 189 pounds.

The 5 tank is not the heaviest size of oxy acetylene tank you can get. The WK acetylene tank is shorter than the 5 tank but is the widest on the list. That makes it the heaviest, at a whopping 220 pounds. 

How Much Does a Tank of Oxy Acetylene Cost?

The cost of a tank of oxy acetylene will vary depending on the size you are getting. This makes sense because you will obviously pay more money to get more gas. 

Small tanks, such as the MC, only cost about $50. Most of the bigger tanks clock in at around $300. That is about six times the price of the small tanks, although you are getting much more gas per dollar.

An important question is how much a tank of oxy acetylene compares to other common fuel methods. A tank of oxy acetylene is less expensive than a similar amount of plasma fuel. Although a tank of oxy acetylene is more expensive than a tank of propane, it is also more efficient, so it will last longer.

How Much Oxy Acetylene Will You Use?

How much oxy acetylene you will use can help you determine how much you need to buy. You want enough oxy acetylene on hand to fuel your entire project; otherwise, you’ll be met with an empty tank mid-weld.

The answer to how much oxy acetylene you will use depends on a few factors, including:

1. The thickness of the metal
2. The intensity of the flame
3. The type of welding (heavy metals or emittive fluxes)

The flow is measured in liters per hour, or L/hr. The lowest is about 70 L/hr, while heavy-duty projects can have a flow of over 800 L/hr. Here is a table that can help you determine how much oxy acetylene you will use and which filters to use for your helmet.

Due to the many factors affecting oxy acetylene flow, it’s difficult to say how much oxy acetylene you will use. When in doubt, go to a supply store and explain what you are working on to the workers. They can give you personalized advice on what type and size of tank to get.

Another Factor Affecting Which Size Tank to Get – Storage Capacity

Obviously, when shopping for an oxy acetylene tank, you need to think about how much you are using for your project. Another factor is your storage capacity. Oxy acetylene is a very volatile gas. You must follow special procedures to store your tanks, including storing them upright with their valved caps screwed on tightly. Don’t get a tank so big you don’t have anywhere to store it in your workshop.

What Is Oxy Acetylene Used For?

Although oxy acetylene is a volatile fuel, its many uses make it a popular choice. Here are some of the many uses:

• Welding thin metals
• Torch welding
• Melting sturdy metals such as steel

Oxy acetylene works with different welding tools, including torches. It gives you more control over the heat, making it ideal for thinner metals. It produces a hotter flame than other gases, making it ideal for melting steel if you don’t have access to welding equipment more powerful than a torch.

Final Thoughts

If you have a welding torch, oxy acetylene is an important fuel source to have on hand. In the United States, this fuel comes in tanks of ten different sizes that differ in height, weight, and gas capacity. 

The post What Size Oxy Acetylene Tanks Should I Get? appeared first on Beginner Welding Guide.

This article aims to provide answers to the question of whether you should use magnetic welding clamps and grounds by addressing the pros and cons of their use, concerns about durability, cost of the equipment, and some potential alternatives. 

When Do I Need Welding Clamps?

While you could weld without a clamp, keeping the metal at the desired angle and position would be very difficult. Basically, welding clamps increase accuracy and precision, allowing for clean seams and quality workmanship. They also help a welder to concentrate on welding instead of constantly having to readjust the pieces being worked on.

When used to hold pieces in position for welding purposes, a welding clamp should be clamped down on all four sides. This will ensure that the two pieces of metal are held firmly in place and prevent twisting during the process.

Different Types of Welding Clamps

There are a variety of types of welding clamps that can be used. These include:

C Clamps

C Clamps – These are very basic and can be used for a number of tasks. They do not have the holding power that other types, such as vices, have.

Vice Clamps

Vice-type clamps are very strong and provide good leverage for holding pieces in place. They also have the ability to rotate, allowing for increased flexibility when working with different angles. These types of welding clamps require more storage space than other types due to their size.

Vices come in both stationary and non-stationary (also referred to as “self-tightening”) types. The stationary type requires a welder to tighten the vise manually, while the non-stationary models have a handwheel that tightens them automatically.

F Clamps

F clamps are used for lighter projects. These are easier to use than C clamps but do not provide the same amount of holding power. They also do not allow for as much flexibility since they cannot rotate.

Magnetic Welding Clamp

Magnetic Welding Clamp is the most popular choice for welding applications. They are extremely strong and do not rust or corrode. Magnetic clamps allow maximum flexibility, allowing welders to work with different angles easily.

Why to Use a Magnetic welding Clamp?

The most important reason for using a magnetic clamp is that they are the easiest to use. They require no tools, which means they can easily be attached or unattached with one hand. This is very important when the welder needs the other hand to hold the welding gun.

Pros and Cons of Magnetic Welding Clamps

There are numerous pros or advantages to using magnetic welding clamps and grounds, most of them point back to the reason why magnetic welding clamps and grounds were invented in the first place: for added convenience.

Pros of using magnetic clamps and grounds

Let’s start with all the good things about using magnetic clamps and grounds.

They increase welding productivity

Using magnetic clamps and grounds instantly increases welding productivity. Instead of twisting traditional screw-type clamps in and out, magnetic clamps and grounds allow the user to simply stick a magnet onto the surface of the workpiece and start welding. 

More convenient for welding large workpieces

Welding towards the middle of a large structural, square, rectangular, or circular steel pipe becomes much more convenient. In the case of welding on an oversized workpiece such as pipe, a magnetic welding ground makes grounding your weld – in some instances – possible.

Great for welding where only a portion of the base metal is exposed

In applications where you are welding on a workpiece that has only a portion of the base metal exposed (such as in an automotive repair shop where a body panel is taken down to bare metal only in a certain area) grounding becomes easier or even possible. 

Amazing when welding sheets of metal

Magnetic clamps are worth their weight in gold when welding sheets of metal that need to be constrained in a perpendicular orientation without any elaborate jigs or fixtures. A magnetic clamp can simply stick to the metal in the corner of the joint and hold the workpiece securely. 

They decrease the cost for setting elaborate fixtures

Using magnetics can decrease cost in setting up elaborate fixtures such as in shipbuilding where “dogs and wedges” are used for sheet metal fit-ups. Costs can be decreased in labor by decreasing a two-man job to a one-man job, simply by using an optimized magnetic work holding solution. 

Cons of using magnetic clamps and grounds

Given the many great advantages of using magnetic clamps and grounds, there are some downsides to using them.

Only for Ferrous materials

Magnetic clamps and grounds will only work on ferrous materials. This means that for applications where you are trying to weld aluminum or non-ferrous stainless-steel materials, you will need to find an alternative to using magnets. 

Special attention and care needed

Special care must be used when using magnetic clamps and grounds. Unlike other welding equipment which can be used heavily on a busy job site, magnetic clamps and grounds cannot be thrown into a box, dropped on the ground, or accidentally struck with another piece of equipment. 

The clamp can become demagnetized

If the magnetic clamp or ground becomes demagnetized in part or in full, there is a good chance that the clamp or ground may fall off your workpiece while you are performing your welding job. This can be costly, dangerous, and annoying. 

The magnet can interfere with the weld

In the case where the magnetic clamp or ground is close in proximity to your weld bead, there is a chance the magnet can interfere with the weld puddle and cause arc blow which is very difficult to control and can cause diminished weld quality. 

The magnet can accumulate metal filings

In shops where there is cutting and grinding (most weld shops), there is a high likelihood that your magnetic clamp or ground can accumulate metal filings on the magnet surface and cause extra cleaning of your magnets prior to using them. 

How durable are welding clamps and grounds?

The durability of welding magnets used for clamps and grounds is a common concern for welders. This concern about how durabče welding clamps are is actually backed by science.

Two things that welders do most, preheating materials and hammering the workpiece to remove slag from the weld bead.

The science behind the diminishing magnetic field (demagnetization) is based on the strength of the magnetic dipoles of the material.

When either high heat or a high amount of vibration traveling through a magnetic field, the magnetic dipoles are disrupted and change their orientation to become less magnetic.

When a magnet is heated to a temperature called the Curie point (different temperatures based on the base material) the magnet’s strength will be decreased.

Therefore, in order to maintain a magnet’s strength, you must treat it with at least a minimal amount of care so that the magnetism of the tool is maintained. 

One important area to be aware of is the amperage rating of your magnetic welding ground.

NOTE: Using an incorrectly rated magnetic welding ground can cause your magnetic welding ground to demagnetize and/or cause a dangerous arcing situation. Use the properly rated magnetic welding ground for your application. There are different amperage varieties on the market including magnetic welding grounds rated anywhere between 300 and 600 amps. 

Cost of Magnetic Welding Clamps and Grounds

High-end magnetic welding clamps and grounds have higher quality, magnetism strength, and long-lasting durability. Some brands that fall under this higher-end category are Magswitch, Industrial Magnetics, both of which cost a bit more than other brands.

In the case of magnetic welding clamps and grounds, you really get what you pay for since there are varying quality levels in this product category.

If you need a larger, stronger magnet, you should expect to pay more for it than a smaller weaker ones. 

On the other end of the spectrum are the super economical versions of magnetic welding clamps and grounds.

NOTE: The only reason that I would recommend something this economical (and most likely cheaply made) is if one of my friends was looking for a “throw-away” set of magnetic welding claps that they would only be used for one project then not need them anymore.

Magnets at this price point are made from lesser quality materials and therefore have lesser durability over time.

The last thing you would want to happen while you are performing a weld is for either your clamp or ground to come loose from your workpiece – not only is this dangerous, but very frustrating.

Alternatives to Magnetic Clamps and Grounds

When magnetic welding clamps and grounds are simply not an option, whether there are issues with the workpiece ferrous qualities, workpiece sensitivity to magnetic fields, or an absolute need for ultra-high-strength clamping, there are always alternatives.

After all, steelworkers, or welding professionals in general, have been constructing countless welded structures for over one hundred years now.

The typical solution for abnormal clamping and grounding situations is to weld either a dog or a stud onto your workpiece.

In the case of a necessary ultra-high-strength clamp, a dog might be welded onto a plate of material, and in conjunction with a wedge, a plate can be moved and clamped into position for welding.

Shipyards always use this clamping methodology since they regularly weld together large plates of material while holding tight tolerances.

On a smaller scale, in instances where a welding ground is needed, and magnets cannot be used, a bolt or a stud can be welded (or spot welded) to the workpiece for the sole purpose of grounding the weld, then it can be cut off and ground smooth after the weld is complete.

This methodology can be used in applications where the workpiece is non-ferrous such as with aluminum and stainless steel.

Conclusion

Expert welders agree that 99 percent of hobbyist welding applications don’t require magnetic welding clamps or grounds – the scope of hobbyist applications are simply limited enough only to require the use of conventional clamping and grounding methods.

If you have either determined that you need magnetic equipment for your welding application or if you need assistance, deciding on this type of equipment it is strongly recommended to visit your local welding store.

Your local welding store typically has someone there who is very knowledgeable in welding equipment and will be happy t assist you. 

Related Questions

Read Next

• How to demagnetize metal for welding?
• What are the causes of welding spatter?
• Why Use a Welding Apron?
• Best Welding Helmets for the Beginner
• 7 Tips for the first time welder
• What do I need to start welding?

The post What are Welding Clamps Used For? appeared first on Beginner Welding Guide.

As you might imagine, burns are the most common injury for a welder. 20-25% of them result in a hospital visit.  Spatter and sparks can cause second and third-degree burns. They can also ignite clothing materials.  

What are Welding Aprons Made From?

Welding aprons are typically made from durable, heat-resistant, and flame-retardant materials, such as leather, split cowhide, or heavy-duty flame-resistant (FR) fabrics like cotton or synthetic blends. These materials provide protection against sparks, spatter, and heat, ensuring safety during welding tasks.

The use of aprons whether made from traditional cowhides or unique pigskins provide a high level of protection when any welding task is involved.

There are two basic types of aprons available. There are half aprons that offer lower waist protection and full aprons that protect the welder’s entire front side.

I highly recommend the Lincoln Electric welding leather apron very reasonable priced.

Some aprons are made of heavy denim or cotton. These are available at very reasonable prices compared to their leather counterparts. High-quality aprons use flame retardant cotton to better protect the welder from high heat or even open flames.

NOTE: It is crucial to know that some of them are only flame-retardant treated. These will lose flame resistance properties after laundering.

Also, keep in mind that excessive heat from welding can cause colors from certain aprons to spill onto your clothes.

How to Choose a Welding Apron Style?

It is important to pick a comfortable style. Make sure it fits well because an uncomfortable piece of clothing is less apt to be worn. A comfortable fit can assure a smoother welding operation even after long periods.

You might find welding aprons that wrap, clip, or tie at the waist, protecting the waist down, more comfortable. Of course, a welding jacket of some sort will be needed to protect your upper torso.

Others may prefer a full welding apron that looks similar to a chef’s apron. Obviously, these one-piece aprons provide more coverage and protection.

Welders come in different sizes so various length aprons are available. Consequently, picking the right cut and style is fairly easy whatever build you may be.

You will want to consider your welding style and the welding tasks at hand when picking the best aprons to use. For instance, long aprons are better in providing more protection and safety. But, it is crucial to also put into consideration mobility and practicality.

Half-cut aprons offer lower protection than longer aprons but provide more mobility and comfort. To get both mobility and coverage, split leg welding bibs is definitely the way to go.

Different Welding Apron Types

For different scenarios, several types of welding aprons are advised. I’ll go through the most common types/groups of welding aprons and show you some photographs so you can figure out which one is right for you.

Basic Protective Aprons

These aprons offer comfort, light weight, adequate protection, and convenience. They are used in some industries that include healthcare, maintenance, manufacturing, and carpentry. Some of these aprons are used in lab settings and some are even disposable.

NOTE: For welding, never use or wear anything besides heavy denim, cotton or leather. Never use plastics or polyester-type materials as they can melt to your skin.

Flame-Resistant Aprons

Such aprons works best for work environments that expose users to flame, intense heat or electric arc. These are flame-retardant aprons that offer needed protection in situations wherein users are exposed to high heat or open flame.

Lets look at different Flame resistant apron styles:

Split leg style that snaps or ties behind the knee; sort of like chaps for cowboys or motorcycle riders:

• Convenient Split Leg Design
• Heat & Flame-Resistant heavy duty split cowhide leather
• Extra Long (24 inches wide x 42 inches tall) full coverage
• 3 pockets for tools and work accessories

Check Price On Amazon

Side split option where the top front is covered and it ties in the back, like an apron:

• Genuine split leather hide and reinforced in areas that have more stress
• High-quality flame resistant Kevlar stitching
• Covers you from upper chest to below your knees
• Heavy-duty harness strapping across the back that’s easy to adjust and clip/unclip

Check Price On Amazon

Full jacket that snaps up front and made of fire resistant material is available:

• Heat & Flame-Resistant heavy duty split cowhide leather
• Full coverage Leather Jacket protect you when you are working
• Open back keeps you cool in a warm shop or in summer
• Stitched with strong US Kevlar heat resistant thread

Check Price On Amazon

Full-length apron made of leather with the tie at the neck and back:

• Apron for protecting clothing and skin from welding spatter
• Made of heavy split cowhide for durability
• Flame-resistant for protection from flame and spatter
• Adjustable harness system for proper fit and weight displacement
• One size fits all

Check Price On Amazon

Complete bodily protection, a full suit much like overalls is offered:

• Heavy duty cowhide split leather
• Anti-flame retardant
• Safe and effective high collar protection
• Protecting the arms and torso from welding spatter and heat

Check Price On Amazon

Other Safety Gear You Need

Wearing the proper protective equipment or PPE can protect you from the elements of the job. For eye protection, welders must use welding helmets, safety glasses, and goggles when appropriate.

Flash burns are no fun and very painful. As is digging slag out of ones eye. Donning a flame resistant jacket or bibs can save on purchasing new work clothes every month in addition to protecting your skin from burns. 

For hand and arm protection gloves and welding sleeves are important. Especially if performing vertical or overhead welds.  

Depending on air particulates, some jobs may require a respirator. When in doubt, use one. It is always better to be safe than sorry.

Your work welding boots are also important as slag falls to the ground at your feet. Jobs may require steel-toed boots due to safety issues surrounding the product being worked on. 

On a personal note, I also found that wearing a welding hat, like a baseball cap, but sort of like a beanie, is helpful and comfortable to wear under your welding hood. Besides keeping your hair protected, it helps to keep the welding hood on snugger.

TIP: Read my interesting article about welding caps and why they are made like they are.

It is important to do your research and choose your personal protective equipment wisely. Choose less based on price, but more for comfort and that it performs to your needs.

History of Welding Protective Clothing

It is interesting to contemplate how the use of protective clothing evolved along with metal working throughout history.

It is believed that the history of welding began in Egypt around 4000 B.C. where the first metal used was copper.  Eventually, bronze, silver, gold, and iron were used. Especially, when forging swords out of hardened solder.

Ironwork started around 1000 B.C., with the shaping and bending of the
iron metal by using furnaces to produce swords and spearheads.

In the Middle Ages, the closest thing to welding were the tools used by a blacksmith. The metal would be heated in the fire until it was soft and moldable, or beat with a hammer on to an anvil.  

As the metal cools it loses its pliability. Consequently, heat will have to be added repeatedly until the proper shape is acquired. The metal can then be forged into a sword or spear for weapons. The metal can also be made into jewelry and ornate metal boxes.

Origins

In 1880, French Scientist August de Meritens patented the process for carbon arc welding and it became a popular method of joining metals.

An American inventor patented the first arc welding process using a metal electrode in the 1890’s. The metal electrode melted the metal and joined the two metals with filler.

This is still practiced today. In the 20^thcentury gas welding was perfected and research into gas shielding of the arc and weld area led to important breakthroughs.

Since those very early years, techniques have improved dramatically. Plus, various ways to unite other metals have been discovered. MIG and TIG welding are great examples. 

Related Posts

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• What are the causes of welding spatter?
• 8 Tips for MIG Welding Beginners
• How to select Welding Amperage?
• Beginner tips for start welding
• How to Use a Plasma Cutter?
• Vertical Stick Welding Tips
• The Best Welding Machine for Beginners
• Beginner welding projects

The post Why Use a Leather Welding Apron? appeared first on Beginner Welding Guide.

Fortunately, there are a plethora of ideas out there? Ideas that do-it-yourselfers have come up with that I probably would never have thought of on my own. Plus, commercial carts of various styles and brands are available to choose from.

I should probably start by deciding how many machines I want my cart to hold. Then, decide what other tasks I might want the cart to do.

Such as:

• Should welding cart have drawers or shelves?
• Will you need it to carry a gas bottle?
• Should I add hangers for welding helmets and other tools?         

One thing is for sure, I will make sure it’s constructed of solid steel and has good, heavy duty casters.

Then, it’s a choice of buying one or finding some plans and building a custom welding cart. A third choice is to draw one up with exactly what I need leaving off everything I don’t need.  

Do You Need a Welding Cart

Once you assess your needs, there are a few different paths you can take too. As mentioned, most DIY’ers and pro’s build their own carts. Again, either from some existing welding cart plans they find online or from a fully custom, self-designed cart. You have the same choices.

It can be hard to find a store bought cart with all the features you want. Having said that, it will save you the time if you need a cart quickly or don’t have the time to build one.

In this article:

• you will learn about some typical plans available online.
• some good, and not so good, store-bought welding carts will be reviewed.  
• some helpful hints, If you build your very own cart, will be provided surrounding the specific areas you should NOT cut corners on.

The goal here is to provide you with helpful information so you can decide between builing building a welding cart or purchasing one off the market.

In part, we will do this by providing links and resources to help you decide. It is possible that you might find a premade cart on Amazon that will fit your needs better than something you could build yourself at this time.

So, let’s dig in and start exploring some welding cart ideas.

Welding Cart Plans

There are many good plans available online. There are also some low-quality plans. Consequently, we will need to sharpen our focus a bit.

This is typically done by asking pertinent questions to help refine our needs. Once whittled down to a workable concept, we can then select a plan that best fits our needs.

For instance: 

• Will it need to hold one machine or multiple machines?
• Does it need shelves or a possibly lockable area?
• Can it be a bare-bones cart just for your welder and/or tank?
• Does your welding cart need to be transportable?
• Will your cart need to carry peripheral equipment such as chipping hammers, wire brushes, ginders, etc.?

Once you know the tools and equipment you need your cart to hold, you can start looking at some welding cart plans.

I have put together a guide to everything you need to think about before building your own welding cart at home.

A quick Google search will turn up several options; here are some that I like right away:

• An Instructables page gives you step by step instructions on how to build a simple cart for your garage or shop. What I like about this plan is that it is a cart that makes use of scrap metal. The writer mentions he used steel bed frames he found at thrift store. Waste not, want not as they say.

• I also like the Miller welding carts page because of the pictures. It’s from their user forum and you’ll see several homemade carts that have been submitted. While you won’t have the dimensions or a ton of information about the cart, what you will get are some great ideas for your welding cart. When designing my cart I stopped here first and sketched out ideas I liked – which helped me plan for drawers, a cord station, a good tank cap space, etc.

• Now, you’ll see crazy stuff on Pinterest, like a welding cart made from a wheelchair, But outside of that you’ll get some good ideas like you would on the Miller forum. I suggest you spend 15 minutes on Pinterest and see what carts catch your eye– you can then incorporate some design features into your welding cart plans.

Let’s say you want a premade welding cart plan that you can simply print out, grab your metal and get busy. Take a quick look at these.

• I would call this one a miller welding cart, because it was designed for a miller machine. It is a solidly built cart and the plans are well laid out. If your machine has the same dimensions (or you want to make your own measurements around this concept), this might be a good plan for you.

• Lastly, this is one great cart built from scrap tube steel. It’s as basic as it gets!

So when it comes to cart plans, you can either draw your own plans based on carts you see online or print out some ready-made plans and start fabricating. 

Commercial Welding Carts

You may not want to be bothered with building your own cart at this time. It is possible that you want something you can just assemble with no hassle.

If we look at our major options and start with the big 3 welding brands, Miller, Hobart, and Lincoln. All these manufacturers produce some top notch welders, so in theory, they should have good accessories. Let’s explore some of their best selling carts now:

Hobart Welding Carts

Now I did a quick search and found only one Hobart cart. It’s a simple, low profile cart. The reviews are kind of a mixed bag, so for the cost, I would skip this one.

I believe Hobart really added their welding carts as an afterthought to their welding machines. They did offer a deluxe cart that seemed like it would have been pretty nice. Unfortunately, it’s been discontinued. I love the Hobart welders, especially the Hobart 140 for beginners, but skip their carts.

Pro-tip: I believe that, for all practical purposes, Miller and Hobart are the same company. So I think they distribute their better carts more often under the Miller name.

Miller Welding Carts

Again, the carts here seem limited and a little on the expensive side. I found this cart and was not impressed. It’s basic, it’s not a welding cart with drawers and the running gear seems suspect at best.

I also found this Migrunner cart from Miller. But oh my the price! I could buy a very basic welder, build a cart from scrap and get a great hood for less than the cost of this cart!

Lincoln Welding Carts

I found one basic low profile cart from Lincoln. There are only a few reviews on this cart. Outside of this model, I can’t seem to find anything else available from Lincoln. I would skip this cart too.

Other Brands

With the explosion of Amazon, there are a lot of imported goods from small manufactures with unknown brand names being sold. A lot of these carts are a mix of value and durability – said another way – you’ll get a semi-decent cart for a good price.

For an in-depth review from us, take a look at this article about the Klutch Compact Locking Welding Cabinet.

Here are some choices:

• The Yaheetech cart has three tiers and is constructed of steel. There are some concerns about the castors rubbing against the bolts, and depending on the welder you pair it with, the possibility of a tip over.

• This is a generic brand two-tier cart. Same issues as we found with the Yaheetech cart (poor instructions, bolts rubbing against the tank or welder). But, it might be in your price range and those issues could be something that’s manageable. 

Outside Amazon there are the Harbor Freight welding carts that are worth mentioning:

• There is the basic Chicago electric cart– which has a 100lb working load and seems straightforward. This is a no-frills cart that might be worth picking up if you’re a beginner welder.

• Now, the welding cart with drawers, or welding cabinet as HF calls it, is a bit more money. But the reviews are pretty good and I like the storage drawers myself.

Thoughts on Commercial Carts

There are some well-made carts you can buy on the market, and some not so well made carts. Overall I would steer clear of anything you can buy. If you’re not a straight up new welder, then why not take the time to make something sturdy yourself? Yes, it will cost about the same as a cart you can buy or more. Yes, it will take more time to build it – but it will probably last a lot longer than any welding cart you can buy.

Conclusion

In this article, we looked at many of the options you have for a new welding cart. You can build your own from premade plans, go full custom and fabricate your own unique cart, or simply purchase a ready to assemble welding cart.

I think the best mix of value and durability would be to build your own welding cart with drawers. You’ll have a cart you’re proud of, a place to store all your gear and a cart that will last you many years.

The post Should I Buy or Build a Welding Cart: DIY Cart Ideas appeared first on Beginner Welding Guide.

If you are a beginner, you may have never heard of a pancake welding hood. They get their name by typically being round and utterly flat as a pancake in the front. Depending on whether you are right-handed or left, one side will have a shield to protect the opposite side of the face from welding sparks and UV rays.

I was first introduced to them in my late teens by a pipeline welder. And, when you try one, you will find they have a feature that makes them indispensable for welding outside. That feature is the balsa box that acts as goggles. This component sets the pancake hood apart from everything else on the market.

The balsa box is actually a small box made of wood that surrounds the eyes and acts as a holder for the lenses. Being made of wood allows the edges that contact the face to be sanded or otherwise shaped to fit. Proper fitting removes any pressure points and ensures the box seals out light entering from every angle.

What does the balsa box in a pancake welding hood do?

This ability to seal out all light that might reflect off the inside of the shading lens helps provide the best, glare-free vision possible. Consequently, this is very helpful for those who weld outside or in close proximity to other welders.

They’re popular among pipeline welders because of the balsa box, which allows them to work with the sun right behind them. When using a regular welding helmet, bright light reflecting off the back of the filter glass can obstruct your eyesight.

When utilizing a pancake hood, flash penetrating from behind the hood from surrounding welders is no longer a concern.

To learn more about UV rays and how they affect the eyes, please see my post, “Will welding damage my eyes“.

In addition, the balsa box is usually painted black on the inside to minimize reflection from the welding arc on the inside walls of the box.

What are pancake welding hoods made of?

The balsa box is constructed of balsa wood where it contacts the face. Other parts of the box that may need to be a bit stronger are often made from pine. Around 95% of the commercially used balsa wood comes from Ecuador.

Balsa wood is very soft and lightweight. The softness of the balsa wood allows shaping for proper fitment to be done easily with just sandpaper. The lightweight balsa box helps keep fatigue down for the user who might weld several hours a day.

Pancake hoods typically come with a wide, adjustable headband that secures the balsa box to the head. As a result, the width of the band helps spread the pressure points out over a larger area, making it more comfortable.

The outer shield is sometimes made from a single piece of molded phenolic like those made by Original Pancake Hood. Other brands are typically made with two pieces of phenolic or similar material that are secured together with screws and brackets made of wood or metal.

Should You Buy Pancake welding hood?

While other hoods do some things better, Pancake hoods are the best welding hoods on the market for welding outside from awkward positions.

They can also be used indoors, and most will accommodate an electronic darkening lens if preferred. Some pancake hoods can be ordered with a flip-up lens. A flip-up lens allows for the clear viewing of your project and surroundings without the need to remove the hood.

The prices are very reasonable, and I think more people would have a pancake hood in their shop if ever given the opportunity to try one.

If you here you will see Pancake Hood I bought for myself.

Related Post

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• Why Use a Welding Apron?
• How to select Welding Amperage?
• Should I Buy or Build a Welding Cart
• How to Use a Plasma Cutter?
• 7 Useful Vertical Stick Welding Tips
• The Best Welding Machine for Beginners

The post What is a Pancake Welding Hood? appeared first on Beginner Welding Guide.

Flash burns of the eyes are usually associated with the welding process. However, if you have seen many flashy-colored welding caps worn today, you might think the term originated with them. Why do welders wear welding caps?

What is the origin of the modern welding cap design?

The history of the welders’ hat or cap, may be lost to time. There is a story floating around (wives tale or not) about a welder who, years ago, fell to his death while constructing a boiler. The crew took up a collection for his widow to help her out in her time of need.

She was grateful to the point that she wanted to repay the crew for their generosity. So, she decided she would make each one a hat. All she had for material were scraps of varying designs and colors. The men accepted them as they were and wore them.

In time, the crew realized that the design was actually beneficial. Especially for keeping welding sparks and slag out of their ears. Soon, they returned to the widow and paid her to make them more of these now-called modern welding caps.

Regardless if true or not, the design of the welding hat has been around for decades. Several mom-and-pop sewing shops across the country custom-make their own variations of these caps. But the basic design is still very much alive and well.

It may very well be that the welder’s cap is an offshoot from George Kromer’s railroad caps. Kromer’s caps were first designed around the turn of the 20th century. They do largely resemble welding caps. Kromer does still sell caps, including welding caps. Check them out here on Amazon.

How to wear a welding cap?

When you wear a welding cap like a typical hat or cap, it will ride snuggly just above the ears. This will leave the crown protruding high above the top of the head. The look takes a little getting used to, but a well-made, nice-fitting welding hat can be quite comfortable.

When welding in odd positions, such as to one side, the hat can be pulled down over the top of the ears with the bill turned to cover the ear on the high side. If you have ever heard the sound of your own ear wax crackling from red-hot welding slag, you already know how beneficial this can be.

Overhead welding is challenging in more ways than one. Unless you want to learn some new dance steps, a welding cap with the bill to the back will keep hot sparks and slag from falling down the back of your shirt.

Also, when the welding cap is pulled all the way down, more head area is protected from hot sparks. If you have hair, it will be thankful.

What is the purpose of the floppy bill on welding caps?

A short bill that is softer and more malleable than your typical ball cap bill is easier to fit underneath a welding hood.

If the bill is too long or protrudes straight out as many wear them now, they will have a hard time fitting under a welding helmet. A shorter bill with a slight downward angle to it readily protects the ears and neck while easily staying tucked away.

Welding caps can be custom-made in several configurations. A longer, stiffer bill is an option, as is a shorter crown. I suspect these are more for casual wear than actual work. They can also be lined for colder weather and comfort.

What are welding caps made of?

Normally the welding cap will be made of 100% cotton. Never wear anything nylon around hot work such as welding! As casual wear, they will be more comfortable in winter than in summer since they do not breathe well.

Since welding caps are 100% cotton, they tend to shrink when washed. This means that if it fits perfectly when you buy it, it may not be after a washing or two. Unless you make sure to wash your caps in cold water and use a low dryer setting. It’s even better just to let them air dry.

Are welding caps great for casual wear?

Growing up, I knew an older gentleman who was a welder at a nearby gas plant. Everywhere he went, he wore his welding cap. Several people remarked that they had never seen him without it.

A friend of mine once worked a summer as a welder’s helper for him, and consequently became good friends. My friend went to see him at his house after the welder had missed work due to a lengthy illness.

When he walked into his bedroom, there sat the old welder sick in his bed wearing his welding cap. He passed away a few years later, and I can’t help wondering if he is still wearing his welding cap.

Read Next

• What is a pancake welding hood?
• Why are welding caps made that way?
• What do I need to start welding?
• How to select Welding Amperage?
• Why Use a Welding Apron?
• 8 beginner Tips for MIG Welding

The post Why Do Welders Wear Welding Caps? appeared first on Beginner Welding Guide.

Working in a shop or garage without a welding table can easily be done. I’ve been doing it most of my life. But I’ve always wanted one. There has always been a desire to build one. There were a thousand instances where I’ve said to myself, “A welding table sure would be handy right now.”

I now have one started and plan to finish it soon. And, I know the moment it is complete, and I use it for the first time, I will wonder why I hadn’t built it sooner.

The fact that I am finding it more time-consuming to resume standing from an, ‘all over the floor position,’ is making the decision a little easier for me to make. It’s way overdue!

I think a great early project for a beginner is to build a metal welding table. It will be great practice and you will rarely need to weld from the floor after building it. You will enjoy welding much more by having your project at a height that makes welding less cumbersome. In addition, your welding has a good chance of progressing much faster if you can weld more easily and more comfortably.

The chances are greater that you will spend more time welding if you are more relaxed. An increase in practice time equates to increased experience. More experience equates to better welders.

How to build a metal welding table?

My welding table will be 48″ x 48″, which will be smaller than most but will suit my needs just fine. It will be constructed so I can easily slide a vice on and off to get it out of the way if necessary.

Features of my welding table:

• My bench grinder and bench-mounted sander will be set up to attach and un-attach easily. They will be stored out of the way underneath the table when not in use.
• The frame is made out of 2 3/8″ tubing.
• The table top will be a half sheet of 3/8″ steel. If it were going to be twice as large, I might consider making the top out of 1/4″ to keep the weight down.
• It will have a 48″ long V made of 2″ x 2″ angle iron welded to one side. These are handy for laying joints of round or square tubing or even angle iron. When laid butt to butt they are aligned perfectly straight for tacking.
• Heavy-duty casters that lock will make it fully mobile yet immobile enough when the wheels are locked so I can get a little rough with my work without having to worry about scooting around.

How big should your Welding Table be?

Your welding table should be at least 4 feet wide and 4 feet in length with a thickness of 1/4 and 1/2 inches thick, and a height of 28 inches.

This will be directly proportional to the amount of space available to you. Unless you have a very large area far enough away from anything you don’t want welding or cutting sparks to come into contact with. It should probably have casters for mobility.

PRO TIP: Build the top out of as thick of sheet metal that you can without busting the budget or creating something so heavy it is no longer mobile. That is if it is meant to be mobile.

Should You build an overhanging tabletop or not?

Leave some overhang on at least one side, if not all the way around, to allow you to get close in. The closer you get to your work, the more comfortable you will be. Make sure your base is stable enough, so your table has a zero chance of toppling over.

NOTE: If your feet have room to fit under the stand then you will not need much overhang, if any at all. It's all about reducing the amount you must bend over in order to reach your project on the table.

Should you build shelving on your welding table?

A working area where space is limited can always make use of additional storage. The most often used items for your welding projects need to be close by but yet out of the way when you don’t need them. Having them on shelves directly underneath the work area will save time.

PRO TIP: In order to keep weight down, consider using expanded metal for the shelving.This not only reduces weight but allows any grinding dust or slag to fall through. You will have less dust buildup on your shelves to contend with.

How can I make devices easily detachable from my welding table?

The preferred way is to use square tubing. How large the vice is will dictate how heavy (thick wall) the square tubing will need to support it. I would stay within the range of 2″ to 2.5″ square tubing.

1. Find two sizes of predetermined wall thickness due to vice size, where one will slide into the other with little to no room to spare.
2. The receiver will be the larger of the two pieces of square tubing.
3. A square tubing stinger welded to a plate to mount your vice will slide into the larger permanently mounted receiver.
4. It is up to you to decide if you want to mount the receiver (stationary) portion vertically or horizontally.
5. If you prefer vertically, don’t have the top of the receiver piece higher than your tabletop. This will negate the whole purpose of making the vice removable. This is to be able to clear the tabletop so larger projects can lay completely flat.

PRO TIP: If you want to save time, but spend a little extra, you can utilize receiver hitch parts which are already drilled for keeper pins to hold your vice in place.

How to make my welding table more usable?

The more planning you can do will certainly help in building a very usable table. The great thing about working with steel is that it’s easier to cut, splice, add, remove, and modify than wood.

However, designing it can be more than half the fun of building your table. Think efficiency when you are in the design stage.

You know, not too big, not too small, not too heavy, not too light. Create storage where you can but make sure when accessing your tools that there is no incumbrance to retrieving or putting them back.

Enjoy the process and marry some metal today!

Read More

• Best Welding Machine for Beginners
• How to select Welding Amperage?
• Best Boots for Welding?
• Why Use a Welding Apron?
• Best Welding Helmets for the Beginner
• What do I need to start welding?

The post Do You Need a Metal Table for Welding? appeared first on Beginner Welding Guide.