Steel:
For this project the main structure of the base
And platform is constructed from 16GA(.063)Square Tube. Its important when selecting steel that it be straight and consistent in tone and appearance. Steel always surprises me when it comes to costs. We recently received roughly 400 feet of 20 foot lengths of square tubing, delivered for about 189.00. Sheet metal, however, can often cost much more for a similar weight in materials. The only real tip here is don't accept materials that are obviously rusted and weathered if it can be helped. We all saw what happened to the tin man when he was left out in the rain.... spontaneous human in a stupid costume combustion!
Cutting the steel:
When it comes to cutting steel, and making nice square projects without alot of fill welding it really helps to have the right tools. Luckily we have access to a nice gravity fed band saw. Now while a cheap Jig saw from S-mart or Mega-lo-mart would suffice, there is much more precision with a unit like this. I have been able to find some basic models from about $200.00. Well worth the cost if you plan on much fabrication work. Especially when you are able to cut 4 pieces all the same length at the same time. Just don't sit in or walk bare foot on the pile of filings it makes....
Welder:
When it comes to welders there are several options out there. Stick welders start at about $100.00 for a basic light duty unit. For about $200.00 you can get a basic entry level flux core mig welder. The preferred option is the mig welder. Mig welders are wire fed and alot easier for those just learning. Although if you want to do high power experiments like making buckyballs and doing some basic welding then a basic stick welder may be a better choice. Whatever method you choose, always use a nice welding helmet the appropriate shade for the work you are doing.
The Base Fabrication:
Fabrication of the base is really straight forward. Simply weld the base box, followed by the uprights, and finally the cross bracing. It's really important that the welds holding each piece together are strong and well bonded, else you end up with a project looking alot like some incremental Linux kernel builds when they break.
Platform:
2 X 50"
3 X 28"
Base:
2 X 50"
1 X 48"
2 X 36"
4 X 12"
4 X 14" (45 degree cuts)
