50+ Welding Projects that you can easily do
Updated: May 27, 2021
Welding is so fun and can be a true form of artistic expression. Even if you aren't necessarily making something artistic, just that nature of that molten weld puddle manipulation is unique to each welder. One could almost say that a welder's signature is his/her weld bead. Whether you have been welding for 50 years or 5 minutes, the sky is the limit on what you can create with welding. One of the funnest thing to do is either build something useful and creative but also making something out of repurposed metal.
Welding Project: Metal Art Wiener dog
I had some extra horseshoes, some chain, and some extra scrap metal from an old trampoline that got thrown in the fire. The old trampoline frame was made out of hollow tube which I cleaned up and pounded the ends down to resemble the back. Before tack welding any of the parts together I cleaned them up down to clean metal. I had on old framing hammer head laying around and some washers for eyes so I welded them together too. I had some brown spray paint laying around so I hit the newly made metal art sculpture dog with a couple coats of it. This was a fun project and was able to give it to my nice neighbors at the time as a gift. They had a dog of similar size and stature.
Here is the welder I use for metal art: https://amzn.to/2mlgQ1a
Ornamental Iron Folding Painting Easel or Picture Display
I made this video "DIY Welding Project: How to Weld an Ornamental Iron Folding Easel for Painting or Picture Display" for fun for my daughter's painting display. You can really make some cool decorative easels using different pieces of decorative metal. These are fun to make. I've made and sold many of them in the past. This one was just a basic model and wanted to keep it simple. Easy welding project and they last forever. Easy to fold up and store when not in use as well.
Amazon link to heavy duty easel: https://amzn.to/2xFXTfC
Amazon Aluminum Easel: https://amzn.to/2WsqWeU
Metal House Security Door Frame | Fabrication From Scratch
This DIY Welding a Metal House Security Door Frame | Fabrication From Scratch | Lincoln PROMIG 140 FCAW video takes you step by step through the process I went through getting the metal door frame measured/dimensioned up, materials purchased, and fabricated. I purchased the square tube and hinges at the metal supply store. The welder I used was a 110V Lincoln PROMIG 140 using just inner shield wire and no gas. Gas IS preferable to use but at the time I didn't have a bottle or set up to use gas so I just used 0.035" inner shield wire.
The rest of the project is shown in my other video here: https://youtu.be/mtM26EOOq7o
Link to Lincoln MIG 140 Welder: https://amzn.to/3bSyCgI
DIY Welding Dirtbike Motorcycle Muffler Back Together
Once people figure out that you can fix stuff welding you'll get hit up a lot. This repair video is using Lincoln PROMIG 140 with inner shield wire fed process. Due to the muffler being super thin, dialed the heat to nearly the lowest setting and used tack welds until it held firm. Once tack welds were in place then was able to put a bead in small increments over the top of them. This was done on a Kawasaki KLX 110.
CAUTION!!! The video doesn't show me making sure the propane canister is empty and then drilling it out at the threaded nozzle portion. You will blow yourself up if you don't do this. This creates a relief for the heat/pressure and also ensures there is no chance of any fuel being left in there. Be absolutely sure you have a slit or drill out a large enough hole on this little cylinder or you will be injured. Now that personal safety has been addressed...I had an old empty propane canister, some re-bar and a few horseshoe cutoffs laying around. I always wanted to make a little metal art pig of sorts so this was my prime opportunity. I did fight the thin wall on the propane cannister but let it cool enough to get it the metal to eventually stick. To ensure a proper ground it was necessary to remove paint with my hand held angle grinder and that allowed me to tack on and weld on the legs. The ears were made from horseshoe cut offs and the eyes from car parts. The tail was also a spring I had laying around. Painted it with rustoleum and called it good.
Metal Art Gearshifter Horseshoe Rattlesnake Welding Project
This welding video is on how to make a Metal Art Horseshoe Rattlesnake Welding Project from old junk metal parts you may have laying around. I ended up doing a better paintjob with rattlesnake patterns and eyeballs but regretfully lost those video clips. Poisonous snakes are always fascinating and ended up selling this on e-bay to a snake collector. The tail of course was made from a gear shifter lever off of an old motorcycle. The rest was cut and welded from old horseshoes. The welder used was a Lincoln Pro-mig 140 that plugs right into a standard wall socket. For the welding wire or filler material I used some standard innersheild 0.035” 71T1 purchased off the shelf at Lowes hardware. Metal art is so fun to make and each piece like this turns out to be totally unique and some can make people stop in their tracks.
The paint used was some rustoleum brand metal paint.
One of the challnges of this fun metal art project rattlesnake was to make sure that I did not melt the tail portion which is made of very hard rubber but could easily melt if I got the welding joint nearest the rattlesnake tail too hot. I used extra precautions not to weld too much at one time without letting it cool down before resuming welding again. This is something commonly practiced as well as something to consider when performing welding around various materials in close proxomity of your welding.
Repurposing scrap metal into various animals, shapes, useful items, display pieces, crazy expressions, monsters, weird creations and ornamental iron household items is one of the funnest crafts in which to throw yourself at. Using your imagination and working with your hands to start with nothing but "throw away" junk metal parts and ending up with things to sit back and stare at or even use on a daily basis is very fulfilling. With the welding trade the sky is truly the limit. To make and create cool artistic creations you don't need to be a skilled welder. Although I will say when you start getting into pieces that have any kind of weight bearing requirement, you should know what you are doing. As for doing free spirited artistic expression welding, you can do it with minimal equipment and skill. If you are just getting into it, I recommend you first allocate a safe place in which to perform your hot work as this could possibly cause some serious personal or personal property damage. Also, get some basic safety equipment which includes a welding hood, leather gloves, safety glasses for grinding, and some steel toe boots. Can't hurt to pick up some a long sleeve leather welding jacket as well. You can find them used for cheap.
Single Horseshoe Coat or Lasso Custom Welded Mounted Wall Hook
For this fun and simple Welding Project; Single Horseshoe Coat Rack, this actually takes 1.5 horseshoes.You'll need a welder and a hand held angle grinder or at least some way to cut metal. Sometimes a metal chop saw is used if you can get one. You take one horseshoe and clean it up really good making the surface of your weld prep area able to accept a sound weld. This means getting it down to clean and shiny bare metal. This will increase your chances of making your weld flow the best. You take your 1/2 a horseshoe and hold it perpendicular to the full horseshoe and weld it so it creates your hook. You make drill a couple holes in the full horseshoe for mounting purposes depending on how big the diameter or your fasteners are compared to the tack holes.
Freestanding Metal Fire Pit from Refridgerant Cannister
This DIY fire pit welding project all started with my neighbor donating a scrap automotive coolant canister to me. He works as a mechanic so is a great source for scrap metal and parts to make various welding projects from. This project was one of my favorites to make because it has decorative purpose as well as practical use for festive backyard fires. Additionally, it was nice to be able to re-purpose some scrap metal and turn it into something worthwhile. The first thing that needed to be done was just to make sure this was absolutely empty by drilling a hole in the top. I already could tell that there was nothing left in it but hot work such as grinned and welding on a canister can be fatal especially if you are unsure on what was inside. Neve weld or grind on a closed canister that contained any kind of liquid without first making sure that it is 100% verified empty of liquids and especially residual vapors. Using my hand held angle grinder with a cutting wheel I made a circular cut around the top and removed what would be the lid and set it aside. I tried to make the cut as accurate as possible by hand for aesthetic purposes. I then took some flat bar I had laying around and made a circle the same diameter of the lid and actually used the lid as a template. This circle made from the malleable flatcar was trimmed and welded together to become a solid hoop. Using the same flatbar, four 6 inch piece were cut and end-prepped and ground clean for welding. These same four pieces were welded to the bottom portion of the canister. Care and caution had to be exercised so as not to blow holes in the thin canister metal weld welding these. After tacking the pieces it was time to completely weld them on. I tried to make sure to control my heat by applying most of it to the flatbar and slightly washing onto the thin metal for fusion. Once the four flatcar pieces were welded in place, the hoop was welded to the top of the flatbar pieces. The some expanded metal galvanized chicken wire a flame guard or barrier was created and wired into place through holes drilled into the metal canister. What was created was essentially a flame viewing riser to enable a larger fire but also enable a nice viewing window in which to enjoy the piece and comfort of a good outdoor fire. Then it was time to weld the legs and handles to the new creation. The same welding technique was used here as far as controlling the heat and keeping the majority of it on the thicker piece so as not to destroy the thinner metal. Once the legs and handles were firmly welded out it was time to cool it down, primer it, and then coat it with some high heat spray paint. Ended up using this quite a bit before giving it away as a gift.
Cool welding helmet here:
Cool welding shirt here:
Post-Vandalism Mailbox Rollcage Welding Project
The thugs will be in for a surprise then they take a swing at this thing. After getting my mailbox smacked off the post one too many times it was time to build something that will ring their bell when they take a swing at it. The first part of the video shows the aftermath and what I came out to the next morning. I had some scrap metal around in which to fabricate a metal roll cage for the thing. Some old planter holders made from round stock will do the trick. I bent two "U" shaped pieces and welded extension to each leg of the "U". I had some square tube pieces laying around as well that were .065' wall leftover from another project. I then welded the square tube to the "U" shaped pieces for the base and then a couple of round stock pieces for the top. It's got a mailbox shape to it. Now I welded in more reinforcing pieces since the main frame is welded. Once I got the roll cage or protective cage built for this thing I welded on a triangular elbow piece to the front of it for decorative purposes. I had some old bed rail frames laying around as well so this made perfect mounting brackets to weld to the frame and bolt into the wooden mailbox pole. I then coated it with a couple of coats of rust oleum spray paint. I secured the mailbox to the 4 X 4 post first then I was able to slide the roll cage over the mailbox with no problem.
I screwed it in with some lag bolts. Good to go. Go ahead, punks, hit like you mean it!
My other blog: https://the-avant-garden.blogspot.com
Here's a link to a new mailbox:
Pick up a new one at the link above and make a roll cage for it so this will be the last mailbox install that you need to do.
Sea turtle from car and lawnmower parts
New Metal Framed Shed Door Build From Scratch
This is a DIY Welding Fabrication Project-New Shed Door Build.
My old door was so old it came apart. The previous owner built it. I decided to fab up one that would last. I needed it to match the shed's wood siding and be able to be locked. I have it some style with an old pipe wrench door handle. After all, it is a tool shed.
I decided it was best to make the outer frame out of angle iron as it hugged the corners a little better. I was able to tack it up in place as I had the convenience of my welder being on site and residing in the shed that I was making the door for. Tacking it in place allowed for a perfect fit.
After tacking it into place I tacked some stiffeners up to hold it in place, removed the door frame from the opening then finished the welding on the ground. This way I didn't burn down the shed.
I welded this up with this Lincoln welder: https://amzn.to/2Kxu6JD
Dryer outlet extension cord for Welding
Do it yourself and/or buy the cord here: https://amzn.to/2TRlgrJ or https://amzn.to/2V9Yxss
Horseshoe Xmas Tree
Three Snowmen welded from Automotive Bearings and Valves
Welding Repair of Travel Trailer RV Metal Foldout Stepdown
Horseshoe Xmas Trees
Fabricate a Machete From Lawnmower Blades
This was a fun little welding fabrication project. I found myself with a stack of old steel thick lawnmower blades. I thought what a better idea than to make a homemade machete with them. I used full penetration weld joints. "V" groove joint design both side. I gouged out the opposite side until I got down to clean sound metal, then welded it up. The trick here was to watch my distortion. So rather than weld one side all the way out I welded each side just below flush and then put the covers on it. Once I welded it out I ground the welds so that they were ground flush and indistinguishable from the base metal. I then marked out a radius for the blade and then a cut out portion for the handle. I then used my hand held electric angle grinder with a cutting wheel to complete the cuts. I honed the blade with a flapper wheel. I then used some wrapped twine for a handle. This was the first of it's kind that I made.
Knife with knuckle guards welded from Automotive Parts and Scrap
DIY Welding Project-:Knife with knuckle guards welded from Automotive Parts and Scrap. I had some extra car parts laying around that my mechanic neighbor brought me so I decided it would be a good idea to weld up a lethal zombie killer.
Here's a cool sword: https://amzn.to/2ZZhCnI
How to make an Extension Cord for your Stick Welder-Weld off Dryer Plug
Purchase one here: https://amzn.to/2GMOlkU
Wild West Cowboy
Check out my Scrap Metal Welding Art Project: Wild West Cowboy. The boots were made from old shoe savers and the legs of course from a large horseshoe. The body came from some old wrought iron fence pickets from a fence I helped a neighbor up the street tear down in exchange for the metal and a sweet gate (which I refurbished and sold). The spurs were made from car gears. The cowboy hat I made from an old shoe saver as well. The guns were little mini railroad spikes someone gave me. The rope and lasso I made from old chainsaw chain by welding each link together.
Link to Lincoln Welder: https://amzn.to/2Vt0zFv
Spider made from Chainsaw Chain
Two Wrought Iron Driveway Gates
DIY Welding Project-Two Wrought Iron Driveway Gates Fabricated at home using the FCAW process with a Lincoln PROMIG140 welding machine. Two different styles of ornamental iron driveway gates built.
Here's a link to a great welder that I used to weld this up and many other projects as well:
Sawblade Fencepost Horseshoe Year Round Flower
I used the GMAW process to make this garden art flower project from scrap metal. The blade is an old table saw blade, the horseshoes came from a local Ferrier, and the fence post was just sitting in the ground rusting. I brought new life to it all through welding and some paint.