Arc welding permits great freedom in design with an almost limitless field of fabrication possibilities using standard materials and often the opportunity to rework old junk into useful items. The following sketches are not detailed working drawings but are designed to serve as sample ideas of designing and producing your own goods from existing or readily available materials. Before you commence these or any other projects it is a good idea to carry out these three simple steps.

1. Make a dimensioned drawing.

Rough sketch your general ideas checking for balance of design, feasibility etc., and then get down to the actual details of section sizes, lengths, angles, weld and bolt connection details etc. Don't become weld happy! Allow for maintenance disassembly with bolts where required, e.g. pneumatic tyres must be removable without major oxy cutting!

2. Itemise your requirements and check availability.

It may be worthwhile to modify your design slightly to utilise alternative existing stock. Check back to ensure this alteration has not made a difference to other requirements. If working from overseas drawings, check sizes of local available sections.

There is usually a best sequence of fabrication and assembly and often an impossible one (ever attached an electric light plug without placing the cover over the flex first?) Make certain your procedure is logical and as easy as possible. For example, drilling holes in flat sections under a pedestal drill is much easier than overhead on your back with a portable unit ‑ but sometimes final alignment may warrant drilling at later stages. Similarly, remember to double check before tackling "mirror image" sections, particularly where offset holes and miter cuts on angles or channels are concerned. If a number of sections are to be bent to a particular shape, checking them against a chalked profile on a sheet of hardboard is quick and easy. Usually structures can be built up from a number of sub‑assemblies each capable of being easily positioned for best welding and control.

All dimensions shown are in millimetres (mm).

Bag Truck and Bin Attachment

Bottom cross beam is curved approx 38mm deep and ends bent to provide axle hangers, drilled to take suitable diam. axle welded in place. Bin can be cut from 1800 x 900mm sheet; front, bottom and back bent from one 900 x 450mm half. Other half provides 2 off 760 x 450 x 320mm sections for sides as dimensioned with 10mm right angle bends on edges.

25x3mm top rim section carries hooks to hang over top bar, bottom resting on truck base.

Wheels and Casters

A wide range of serviceable wheels and casters can be made from scrap pipe or tubing. Wheel centres can be solid round (axles) or smaller bore pipe (bearings) to suit job. Forks can be fabricated from three pieces of flat.

Fencing Post Extractor

A length of chain attached to the U bolt and the extractor shown will lift toughest posts. Extra pipe fitted over arm will increase leverage. Typical base plate 250 x 250 x 1 0mm.