Homemade Metal Benches

Have a professional look at your welding equipment before using it, especially if you bought used equipment. Because you will be working with tools that are extremely hot and sharp, it is important to know they are not defective.

Tighten all connections to the torch and plasma cutter, specifically the hose through which the fuel travels. It's unsafe to risk a fuel leak.

Clamp your rectangular tube metal to your worktable. Measure out how long you would like the bench's legs, back support bars and top support bar to be. You can measure these pieces against another piece of furniture you already have. Keep it simple if this is your first bench.

Cut the rectangular tube metal to your desired dimensions with the abrasive chop saw. Smooth the edges with the grinder. Cut tabs out of the sheet metal with your plasma cutter to fill the open spaces in the rectangular tube. Clamp the rectangular tube and weld the tabs to the open spaces with your torch. Grind off the edges for a finished look.

Cut the seat of the bench out of the sheet metal. Lay the sheet metal flat on your work bench. Measure out the desired width and length of the seat and draw it out with a silver marker. Clamp the sheet metal down to the workbench on both sides. Cut through the sheet metal with your plasma cutter. Weld each leg to the seat with your torch, followed by the back support bars and finally the top support bar.

Cut two small pieces out of the rectangular tube to weld vertically on the sides of your bench. Cut a horizontal tube that will lay across the top. These pieces will serve as your armrests. Weld these pieces together and attach them to the seat. Cut and weld tabs in the same manner as above.

Paint your bench with industrial paint, if you wish to make it a different color. Apply three or more coats, letting each coat dry for 30 to 60 minutes.