 The skill of welding, as any welder worth his or her own weight in welding wire knows, is valuable in a wide range of tasks, from repairs around the home or auto to more simple projects that can beautify and enhance your workshop or home. In this installment of Lincoln Electric's "How To..." series, we will take you through the process of building your own metal coffee table.
All of the items you will need to complete this coffee table can be found readily available at your local home improvement store. Estimate this project to take about 10 hours, including cutting the pieces of steel to length. You should be able to purchase the materials needed for this project for roughly $30.00 (not including tabletop).
| Required Tools |
Required Materials |
- Welding Table
- Metal grinder, approximately 5"
- Reciprocating saw or chop saw
- 2 squares - one large standard square and one small carpenter's square
- C-clamps, approximately three to be used to clamp project pieces to the welding table
- Lincoln Electric compact MIG welder
- Welding helmet with appropriate lens shade and safety glasses. See "Safety First" below for additional safety equipment and guidelines.
- Lincoln® SuperArc® L-56™ .025" solid wire
- Gas regulator and hose
- Shielding gas with a 75% argon, 25% carbon dioxide mixture
- Bending jig (if making your own trim pieces - see instructions for making your own trim pieces)
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- 1-1/4" x 1/8" thick square tubing cut to three different lengths:
- 4 pieces - 16" in length to be used as legs
- 3 pieces - 44" in length to serve as the top
- 2 pieces - 17" in length for end pieces
- 5/16" solid steel rod - for trim pieces. Length of pieces can vary depending on your taste (see sidebar for instructions on making your own trim pieces). Pre-made decorative trim pieces may be purchased from the following web sites, and in some cases, may be made to order:
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Check your materials. Lay out the materials in your work area and check to be sure you have everything required to complete the project. Don't forget your safety equipment and fire extinguisher. If you haven't already, cut the tubing to the proper lengths. Check the reference chart for your welder (mounted inside the wire compartment on most Lincoln compact wire feed / welders) to ensure you are using the right settings for the thickness of steel you are about to weld. Test your settings by welding on a piece of scrap before you start.
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 Weld the legs to the end pieces. Using one of the 17"-long end pieces and one of the 16"-long legs, align these two components in a 90-degree angle. Check your alignment work with your big square on the outside edge to ensure an accurate 90-degree angle. Then, clamp the two pieces to your welding table using C-clamps. Line up the leg flush with what will be the top of the end piece. The open end of the leg should be showing. Tack weld on the inside of the angle only. Repeat on the other side of the end piece for the other leg. Repeat the whole process to create the other end piece assembly.
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Welding the center sections to the end pieces. Place one of your end piece assemblies on the ground with the feet pointing up. Attach a piece of scrap angle iron or similar piece to it with a C-clamp to hold it upright, in a manner similar to using a bicycle kickstand (see photo). Place the large square on the ground and line up along the outside of one of the long tabletop sides and the end piece to ensure a 90-degree angle. Use the carpenter's square to ensure a 90-degree angle between the leg and the long table top side piece. Readjust the C-clamp to set the end piece in place. Tack weld the inside of the angle only. Repeat on the other side of the end piece with a second long tabletop side member. For now, tack weld only the inside angle. Next, lay your third long tabletop member in between the two you have already welded, measure to center it, and tack weld only the bottom which is facing up.
Repeat these steps to attach the opposite end piece assembly. |
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 Finish weld the top of the table. Flip the table over so it is standing upright and finish weld the top of the table where the long tabletop side pieces meet the end pieces.
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 Finish weld the bottom seams. Flip the table over again so the legs are sticking straight up in the air and finish weld the seams on the bottom of the table you tack welded in Step 3. |
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 Finish weld remaining seams. At this point, the seams on the inside of the joints have not yet been welded. This is the step to finish weld all of those seams. You will want to manipulate the table in different positions to accomplish the welds. You can use C-clamps to secure the table. Also, make sure the welding machine's work clamp is attached after each time you move the table and before you begin welding. |
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 Grinding the welds. Before any trim pieces are added, it is important to smooth the welds with your grinder. The welds will be inaccessible after the trim pieces are attached. Safety glasses with side shields should be worn when grinding. Also, be alert for sparks from the grinding process. They can possibly ignite flammable materials. Read the Safety section for additional tips on equipment and guidelines.
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 Attaching trim pieces. Tack weld the inside of the brackets only, so the welds do not show from the exterior of the table. You may tack weld just once at each end, or one at the top and two on the leg end (as shown).
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 Clean and paint frame. You now have a sturdy frame to support the tabletop of your choice. Before securing the tabletop, however, clean the entire table with a cleaning solvent to remove machining oils. You may now paint the table with a quality semi-flat paint of your color choice.
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 Secure your tabletop. The tabletop can be of whatever material you desire - wood, slate, glass, tile, etc. It is a good idea to secure the tabletop with adhesive, flanges, or even bolts drilled through the frame and into the tabletop. You will have to determine the best way to secure your tabletop based on what material you choose.
Once you have your coffee table situated in front of your favorite couch, kick your feet up and relax.
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Making your own trim pieces
Printable
Version of Plans (PDF)
SAFETY FIRST
Ventilation
It is important to use enough ventilation to keep the fumes and gases from your breathing zone. For occasional welding in a large room with good cross-ventilation, natural ventilation may be adequate if you keep your head out of the welding fumes. However, be aware that strong drafts directed at the welding arc may blow away the shielding gas and affect the quality of your weld. In planning your workshop ventilation, it is preferable to use ventilation that pulls fume from the work area rather than blows necessary shielding gas away.
Electric Shock
Remember, electric shock can kill. Wear dry, hole-free leather gloves when you weld. Never touch the electrode or work with bare hands when the welder is on. Be sure you are properly insulated from live electrical parts, such as the electrode and the welding table when the work clamp is attached. Be sure you and your work area stay dry; never weld when you or your clothing is wet. Be sure your welding equipment is turned off when not in use. Note that Lincoln wire feed / welders have a relatively low open circuit voltage and include an internal contactor that keeps the welding electrode electrically 'cold' until the gun trigger is pressed. These important safety features reduce your risk of electric shock during any welding project.
Arc Rays
It is essential that your eyes are protected from the welding arc. Infrared radiation has been known to cause retinal burning. Even brief unprotected exposure can cause eye burn known as 'welder's flash'. Normally, welder's flash is temporary, but it can cause extreme discomfort. Prolonged exposure can lead to permanent injury.
Workspace - Protection from Sparks
Before you get started on any welding project, it is important that you make sure your work area is free of trash, sawdust, paint, aerosol cans and any other flammable materials. A minimum five-foot radius around the arc, free of flammable liquids or other materials, is recommended. Extra care should be taken in workshops that are primarily used for woodworking as sawdust can collect inside machines and in other hard to clean spaces. If a spark finds its way into one of these sawdust crannies, the results could be disastrous. If your shop area is too small to allow for a safe radius, please use an alternate area like a garage or driveway.
Gas Cylinders
Cylinders can explode if damaged. Always keep your shielding gas cylinder upright and secured. Never allow the welding electrode to touch the cylinder.
Safety Equipment
It is also imperative to make sure you have all the necessary safety equipment and that you're wearing welding friendly clothes. You should wear:
- Welding gloves - dry and in good condition
- Safety glasses with side shields
- Protective welding shield with a dark lens shade appropriate for the type of welding you do
- Head protection - like a fire retardant cotton or leather cap
- Long-sleeve cotton shirt
- Long cotton pants
- Leather work boots
A fire extinguisher should also be on hand during any welding.
Also, make certain no children are in the area when you are welding. They may watch the arc and can experience retinal damage from its intense light. There is also a risk of a child getting burned by welding spatter.
Finally, see your welder's instruction manual for more safety information. You can also visit the following web pages for additional information.
This
project has been published to show how individuals used their ingenuity
for their own needs, convenience and enjoyment. Only limited details are
available and the projects have NOT been engineered by the Lincoln Electric
Company. Therefore, when you use the ideas for projects of your own, you
must develop your own details and plans and the safety and performance
of your work is your responsibility.
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