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But do you really need to take that much meat out of your studs?

can you give more details of the shelf? I have made some with 3/8 lag bolts. depending on your design the forces may not be that great.

What is the guy on the ladder doing?

I finished up a couple of folding go kart stands. Patiently waiting for spring to return…

OP, I would hate to see this project not get completed. It would probably be worth checking some of the woodworking forums. I bet there are lots of people pot there that can lend a hand. If this was mine and I couldn’t find someone with a portable band saw willing to cut it I would probably use...

That looks like some beautiful wood. Depending on how much useable lumber is there you may be able to find someone that has the skills and machinery that is willing to make your chest in exchange for the remaining lumber.

You may need to cut some out of straight section as well. Draw the cut on the straight section and then measure the width of it vs. the other tube.

you will get better results with the Center punch. You can use the guide for the drill bit as well if you like. There are multiple ways to accomplish this task. Just pick one and don’t spend too much time overthinking it. You got this!

this is angle iron but I think the same technique can be used.

Use the Center punch. It will keep the drill bit from skating. Then it is time to just send it.

There are lots of videos of people demonstrating how to bend square tubing on the internet. I recommend watching a few. I’m sure can get some ideas.

Looks good. We will be much happier with the way it steers.

Yes. 1/2” over that distance will make for poor ride.

You should be able to hear a leak like that. regulator? Gauges? Is the torch leaking?

Based on your expected use you do yourself a favour and stick with 75/25. It doesn’t sound like gas refills are going to be a common occurrence and better quality/ easier welds would be more important.