There are a lot of woodworkers out there trying to incorporate welding and metal work into their builds. This lends a certain aesthetic to any project you are working on, so who knows, maybe you’ve already dabbled in this before. If you have done this before,  then the likelihood is you found some projects that suited you as a beginner. If that’s the case and you’re ready to move on to the next step, you’ve come to the right place. The purpose of this article is to take a look at a few projects that will allow you to move on to the next phase of your learning. Who knows, you might even find something that you are passionate about building.

Before You Get Started

In this article, I have listed five items that you can use to test your abilities and home skills. Having said that, there are a few things that you need to consider before you get started. First of all, you want to make sure that all your safety equipment is readily available and that you have all of the material needed the project. Once you have attained all of the materials, you can start thinking about how to put the unit together. I’ve always found that if I sit down and lay out a simple sketch of the piece, it gives me a better idea of where I’m going with it.

Once you make sure that you have all of your materials and a plan on how to use them, make sure that you have all the tools you need.

The following is a list of all the tools that you will need for these projects:

● Welding Machine
● Angle Grinder With Discs
● Skill Saw/Table Saw
● Drop Saw
● Jigsaw
● Electric Drill
● Orbital Sander
● Angle Grinder
● Router/Router table
● Safety Gear
● Set Square
● Spirit Level
● Paint or Stain
● Wire Brush

Any additional tool needs will be listed with the project themselves.

Metal and Wood Gate

The design I have chosen for this project is a basic rectangular gate that is 72 inches tall and 40 inches wide. You will use the two 72 inch sections of 2×2-inch square metal tubing for the sides. These will be connected at the top and the bottom by the two 36 in pieces of 2×2-inch metal tubing. Then a piece of ⅛ inch plate metal should be cut that is 2 inches wide and 36 in long. This will be welded about 1 inch back across the top, middle, and bottom on the inside to create anchor points for the wood.

Holes should be drilled in the quarter inch plate starting at 3 inches from one side and then every 6 inches after that. At this point you have the basic frame for the gate. Next you will need to mount your wood on the front and back and secure it down with the frame bolts.

Why is this Project Important

While this is a simple design, it is aesthetically pleasing and can be easily modified to get whatever look you’re trying to achieve. It will help you work on your welding and fabrication skills which will allow you to continue on to the next project and be even more proficient when welding.

What Skills does this Project Develop

You will want to make sure the welds are as strong as possible and that the wood is finished and treated to avoid any kind of problem with strength or weather. This project will help build upon your design and joint welding skills and will take you to the next step in your welding.

How Will This Help Me Grow as a Woodworker

Not only do you need to make sure that the wood is treated properly for outside conditions, but you also want to make sure that it looks the part. These gates can be as plain or as ornate as you want to make them. Thinking about how to make the wood & metal fit together and fit the aesthetic of the environment will help you in future projects.

What Materials do I Need

• 2, 2×2 inch square metal tubing, 72 inches Long
• 2, 2×2 inch square metal tubing, 36 inches Long
• 3, 3×36-inch  metal plate, ¼ inch thick
• 12, 1×6-inch pieces of wood, 68 inches long
• 18, 3-inch frame bolts with washers and nuts
• 2, Gate hinges

What Tools are Required

No extra tool should be needed this project

Basic Wood Considerations

When choosing the wood for this project you want to make sure that it will hold up to the weather in the environment that you’re building it for. Hardwoods that are pressure-treated will stand up better to wear and tear outside then an unfinished plank will.

Things To Consider When Tackling this Project

This project is designed to go outside, so you want to make sure that your joints are designed and put together well and that the welds are strong and clean. This will allow the piece to hold up to any external forces that may be applied to it. As I stated above, when choosing the wood you want, always make sure that it is something that will survive in this environment. The goal of all this is to be able to produce an item that is usable for years to come.

Metal and Wood Deck Chair

This deck chair design uses 2×2-inch metal tubing to create a unique look that can be used on any patio.  Using one of the 38 inch tubes, weld the 16 inch tube to the bottom at a 90-degree angle. Then at the end of that tube, weld one of the 18 inch tubes so that when it is in the upright position, the 16 inch tube is slanted slightly down. Then weld another one of the 38 inch tubes on the end of that to create a sort of a b shape with a long tail.  See diagram 2-A

Once you have made two of these for the sides, you will use the 20-inch tubes to connect the sides. One at the top of the back, one at the bottom at the end of the B, one directly under the seat, and one at every weld joint. Once you have done this, weld the spring from the bottom of the seat down to the 20-inch cross brace in the middle at the bottom. This will effectively create the metal frame for your chair. For the wood, I have chosen,1×4-inch slats. To mount the slats, you will start drilling your holes about 3 inches from the back of the seat, going forward and up. Then all you have to do is mount the wood using frame bolts or wood screws.

Why is this Project Important

This project is designed to challenge your joint welding. If the welds are not done correctly, the piece will not support the weight that will be applied once an individual sits in the chair. The spring was added to give the unit an extra bit of support, but the main structure needs to be solid in order for it to be useful.

What Skills does this Project Develop

This project develops your joint welding skills. If the joints are not strong in the piece, it will be weak and will not be able to support the weight needed.

How Will This Help Me Grow as a Woodworker

Since this project is highly customizable, you can modify the wood slats to look like whatever you wish to achieve. Even if you want to carve a design into them. The main thing that you want to make sure of is that the piece fits the look you’re trying to achieve.

What Materials do I Need

• 2, 2×2-inch square metal tubing, 16 inches Long
• 2, 2×2-inch square metal tubing, 18 inches Long
• 4, 2×2-inch square metal tubing, 38 inches Long
• 6, 2×2-inch square metal tubing, 20 inches Long
• 2, 3×18-inch  metal plate, ¼ inch thick
• 2, 3×38-inch  metal plate, ¼ inch thick
• 13, 1×4-inch pieces of wood, 20 inches long
• 26, 4-inch frame bolts with washers and nuts
• 1, Large steel spring

What Tools are Required

No other tools are needed.

Basic Wood Considerations

In order for this project to be useful and efficient, you should choose a harder wood that has been treated. This will allow the wood to stand up to the different factors that may attack it in the environment. Plus, being a chair, it will be used a lot for sitting, so the wood will be under tremendous stresses in that area. Make sure that whatever look you’re going for, that you consider all of these factors.

Things To Consider When Tackling this Project

This project is very customized, so depending upon your skill level with metalworking and the aesthetic of the environment that it will be in, take a step back and look at everything else that will be in that area. While this is a basic chair, you can round off the corners, extend some of the components, or even remove the spring if you feel comfortable with that. Just make sure that whenever you do, that your welds will hold

Wood and Metal American Flag

The wood and metal American flag that I have chosen is a fairly straightforward design. You create the frame using the 2, 1×1-inch square metal tubing that is 28 inches long. Connect them at the top and the bottom with the 2, 1×1-inch square metal tubing that is 43 inches long. This creates a rectangle that is 28 inches tall and 45 inches long. Weld the 14-inch piece of square tubing to the 13-inch piece and attach it in the upper left-hand corner. This will create a 13×13-inch frame where the blue part of the flag would be. The 13×13 inch piece of metal plate is to be welded inside this area. You can either cut the stars into it or paint them on depending upon your preference.

The 4, 2×29-inch  pieces of metal plate will be welded next to where the smaller frame is to create the stripes. Starting with a metal stripe at the top where the red would be, there should be a 2-inch gap between the metal stripes where the wood stripes will fit. Once you get past the frame for the star panel, you will start using the 43-inch pieces of metal plate. You should start an end with a metal stripe next to the frame. You will weld the 26-inch piece of metal plate on the backside of the frame on the right and weld the 14-inch piece of metal plate to the backside along the side of the star panel. Weld the 12-inch piece to the left side under the start panel. These will all create backstops for the wood pieces to be bolted to.

Why is this Project Important

The project will teach you more about finish welding. Making this peace aesthetically pleasing will be an important part of the weld.

What Skills does this Project Develop

This project is intended to teach you to finish weld so that you future pieces will be cleaner. If you hold yourself to a higher standard you will start expecting that from every project. It will also teach you how to finish the wood aspect of the piece to get the desired look.

How Will This Help Me Grow as a Woodworker

Not only should you consider more about what type of wood should be used with a project like this, it is also important how you finish the wood. You can replace the star panel with a piece of wood that is carved or painted. Getting a particular look from wooden stripes will take this project to a whole different level.

What Materials do I Need

• 2, 1×1-inch square metal tubing, 28 inches Long
• 2, 1×1-inch square metal tubing, 43 inches Long
• 1, 1×1-inch square metal tubing, 14 inches Long
• 1, 1×1-inch square metal tubing, 13 inches Long
• 1, 13×13-inch  metal plate, ⅛ inch thick
• 4, 2×29-inch  metal plate, ⅛  inch thick
• 3, 2×43-inch  metal plate, ⅛  inch thick
• 3, 1×2-inch pieces of wood, 29 in long
• 3, 1×2-inch pieces of wood, 43 in long
• 1, 2×14-inch  metal plate, ⅛  inch thick
• 1, 2×12-inch  metal plate, ⅛  inch thick
• 1, 2×26-inch  metal plate, ⅛  inch thick
• 12, 1 ½ -inch frame bolts with washers and nuts

What Tools are Required

If you’re going to do any carving of the wood, you will need chisels.

Basic Wood Considerations

If you’re going to use straight planks or carve the wood, I would use relatively durable pieces of wood. If you’re going to steam the wood to bend it, then you will want to make sure it is a softer wood that will hold up to the procedure. The type of wood stain depends upon what look you are wanting to achieve once you mount the pieces.

Things To Consider When Tackling this Project

A few of the things that you should consider when tackling this project is the overall look that you want to achieve. Are you going to make the flag straight or wavy? If you’re going to use a wooden star panel, you want to decide if you’re going to carve it or not.

Wood and Metal Ornate Dog Crate

The metal frame for this project is relatively straightforward. You start with 2 of the 1×1-inch square metal tubing 30 in long. Then connect them at top and bottom by 2 of the 38 inch long tubs. Repeat this twice to complete the signs. On each side, weld one of the 38-inch tubes 12 in down to create the window where the grate is. Then weld the 28-inch long metal tubes to the corners to connect the two sides.

To create the grate, weld the 12-inch metal dowels inside the window at a 5.4-inch interval. Then weld the 38 inch long dowels at 4-inch intervals inside the same area. Weld all the dowels together at the crossing points and this will create your grate for you. Weld the L brackets and small metal plates inside of the frame to create mounting points for the wood skin to being screwed too. The small panels on the sides should be mounted to hinges so that they can fold down, creating an entry point on the sides if needed. Doors are typically cut in the front to provide access from that direction as well. All of these will need to be mounted to hinges that match whatever the aesthetic of the piece is.

Why is this Project Important

You will want the welds on this piece to be nice and clean so that it fits in any environment. The piece can be an end table if needed so it’s important that it be furniture quality.

What Skills does this Project Develop

Finish welding is an important skill that needs to be refined while doing these projects. Once you have mastered that skill, it will allow you to make a clean piece that is able to carry whatever wood you’re looking to install.

How Will This Help Me Grow as a Woodworker

This project will help teach you how wood and metal can integrate with each other to become a cohesive piece. Not only do you need to make sure that the metal joints are nice and clean, but you want to make sure that the wood you pick is durable.

What Materials do I Need

• 4, 1×1-inch square metal tubing, 30 inches Long
• 4, 1×1-inch square metal tubing, 28 inches Long
• 6, 1×1-inch square metal tubing, 38 inches Long
• 18, ¼ -inch metal dowel, 12 inches long
• 4, ¼ -inch metal dowel, 38 inches long
• 2, ⅛-inch metal dowel 15 inch long
• 2, 28×28-inch pieces of wood,1 inch thick
• 2, 15×38-inch pieces of wood,1 inch thick
• 1, 28×38-inch pieces of wood,1 inch thick
• 1, 31×41-inch pieces of wood,1 inch thick
• 8  1.5×1.5-inch L brackets
• 6, 1×2.5-inch pieces of ⅛ steel plate
• ¾ wood screws for mounting the wood
• 8, hinges
• 5, latches

What Tools are Required

Chisels for the wood carving

Basic Wood Considerations

It should be something that will hold stain well and that will look aesthetically pleasing as a piece of furniture. Consider the grain of the wood and how it will look once it is stained. You will also want it to be a sturdy type of wood so that your dog will not be able to damage it easily.

Things To Consider When Tackling this Project

The main consideration for this project is the size of the unit. The dimensions can be adjusted to fit any area. This makes this project a highly adaptable piece that will fit in any area of the house. If it is going to be used in a living space, you want to make sure that the look of the unit fits in as well. This can be achieved by selecting the right wood and stain for the project.

Wood and Metal Computer Desk

The computer desk that I’ve chosen a relatively simple design. The top of the desk is comprised of two panels that angle slightly out. The backside of each panel is a 40 inch long, 1×3-inch metal tube. The pieces that meet in the middle that are to be joined together are 23.4 inches long. The end pieces are 22 inches long and the front edge of the computer desktop is 32 inches long. Put the other side together so that it matches the picture in diagram 5. You can modify this slightly by changing angle cuts and the length of the tubes involved.

For the legs, you will use the 4×22-inch metal plate as the foot and weld the
2×2-inch metal tube that is 28.5 inches about an inch from the back of the plate centered in the middle. The 29.1-inch tube will be cut at a slight angle so that the top sticks out further than the bottom. Make sure that the tops of both tubes are exactly level to prevent any problems with the top of the desk. The metal leg that will go where the two pieces meet together in the back is simply a 28.5-inch piece of tubing mounted in the middle of a 4×4-inch metal plate.

The small 1×2 inch pieces metal plate will be welded periodically underneath the wooden sections to provide an anchor point for the wood. You want the top and leg inserts to be a durable type of wood. This is so you will not have the type of wear and tear that you would normally see.

Why is this Project Important

This project being just “that little bit harder” will help improve your welding skills and help you get ready to move on to the next level of project

What Skills does this Project Develop

This project will help you improve upon your fabrication and design. It will also help you with your finish welding skills and finish woodworking. Also the combination of all three, makes this is a good project to finish up the article with

How Will This Help Me Grow as a Woodworker

There are so many things that you can do to customize the wood for this project. If you want to carve something into the top or legs, you can cover it with a clear epoxy so that they will still have a smooth surface. However, if you just want to just make some kind of design into the legs so that they can see through or run cables through it, the choice is purely up to you.

What Materials do I Need

• 2, 1×3 inch metal tubing, 32 inches Long
• 2, 1×3 inch metal tubing, 40 inches Long
• 2, 1×3 inch metal tubing, 22 inches Long
• 2, 1×3 inch metal tubing, 23.4 inches Long
• 3, 2×2-inch square metal tubing, 28.5 inches Long
• 2, 2×2-inch square metal tubing, 29.1 inch Long
• 2, 18×28.5-inch piece of wood ½ inch thick
• 2, 16×34-inch piece of wood 1 inch thick
• 2, 4×22-inch piece of plate metal ¼ inch thick
• 2, 4×4-inch piece of plate metal ¼ inch thick
• 23, 1×2-inch piece of plate metal ⅛ inch thick
• 4, 1×1-inch angle iron 10 inch long
• ½ wood screws for mounting

What Tools are Required

Chisel for any carving work you wish to do.

Basic Wood Considerations

The wood for this project needs to be durable, but beautiful. You want to make sure that the grain of the wood shows through so that others can appreciate how the pieces melt together.

Things To Consider When Tackling this Project

The main things to consider when building this computer desk is the size and height of the individual that will be using it. Plus, if it is going to be too big for the area they need to put it in, you can adjust the size down accordingly. This will not only make this a work of art, but it will be a useful piece that they can use for years to come.

In Conclusion

Once you have made it through all of these projects, it should greatly improve your skill as a welder. Considering how the wood that you’re using is fitting in with the piece will improve your knowledge as a woodworker. All together, these projects should take you to the next level in your profession. I can tell you that since I’ve been writing this article, there have been many aspects of both disciplines that I had not considered. However. working on the list and the diagrams have given me a greater understanding of design and the manufacturing of pieces like this.

If you want other projects than what I’ve listed here, do a search of your own and see if you can come up with something that you feel fits your sensibilities. Whenever you do, be safe doing it and make sure that you always have a fully stocked first aid kit that is accessible to you. A first aid kit can be one of the best pieces of equipment you own. My recommendation would be to start with the first project and continue on to the last because they were put together to build your skill with each project. Whether or not you decide to do it that way or you just want to try one, pick a project and get started.