Learning to Weld - Building a Low-Floor Wagon

This project started life as a way to learn to weld, using 25 x 25 mm square steel tube salvaged from a pallet on which a ride-on mower was delivered.  After a few practice welds, I realised there was enough square tube to fabricate a low-floor wagon which would be useful for various duties.

The welder - gasless, flux core variety.

The first step was to fabricate one sideframe, and test the strength of the welds by supporting each end on a brick and standing on the middle.  It passed.

After the success with the first sideframe, I ordered a basic welding table which would greatly assist in aligning the overall frame straight and level.

The wagon frame taking shape on the welding table

Within a relatively short time-frame, a rolling wagon emerged from the workshop.  The low level floor is a piece of chipboard which rests on conveniently located lugs which were already attached to the side pieces.  

Short lengths of 25 x 50 mm rectangular tube, left behind by the previous owner of the house, provided attachment points for the bogie pivots and couplers.

I purchased flat bar from the local hardware store to fill in the end parts of the frame.

Welded areas received a good clean-up and a coat of anti-rust primer, followed by an all-over application of Colorbond Manor Red - the railway's standard wagon colour.

The low-floor wagon is routinely used to transport the lawnmower (normal size, not ride-on) and other garden tools to far flung parts of the garden, and also the carry the wheelie bin to the front gate.