Modifications to the HF 4 and 5 drawer service carts - what changes have you made?

BellyUpFish · May 18, 2014

What are Matt's plier racks?

sdavis622 · May 18, 2014

BellyUpFish said:
What are Matt's plier racks?

http://www.garagejournal.com/forum/showthread.php?t=246146

New Plier Rack

My Garage:
http://www.garagejournal.com/forum/showthread.php?t=243729

PelicanPines · May 18, 2014

Thanks sdavis622... you beat me to it. I should get mine tomorrow, pictures to follow.

sdavis622 · May 18, 2014

PelicanPines said:
Thanks sdavis622... you beat me to it. I should get mine tomorrow, pictures to follow.

No prob! Your cart turned out awesome! I've got a 169 coupon good til sept so I'll be getting one soon and I'm definitely doing the bottom shelf mod. That's the best mod I've seen!

My Garage:
http://www.garagejournal.com/forum/showthread.php?t=243729

PelicanPines · May 18, 2014

sdavis622 said:
No prob! Your cart turned out awesome! I've got a 169 coupon good til sept so I'll be getting one soon and I'm definitely doing the bottom shelf mod. That's the best mod I've seen!

My Garage:
http://www.garagejournal.com/forum/showthread.php?t=243729

The brace is overkill but the dewalt boxes I store down there are heavy. I modified them with that handle and store all kinds of other stuff in them. Letter punches, hole saw sets, trim router, etc. It holds 7 dewalt boxes perfectly.

PelicanPines · May 18, 2014

The Hoffman shelf is taking a bit longer to paint. I have all the pictures and will post them tomorrow. The shelf was white and the surface was a bit smooth so I topped the shelf with paintable rubber under coat, then painted that red to match the box and the rest. The shelf can hold 150 pounds and is the most solid folding shelf I have come across. It's a bit pricey if you get stuck with retail, it actually costs more than the HF box. I got lucky, I snagged a $40 dollar deal on eBay + $15 shipping. The thing is heavy.

Matt_C · May 18, 2014

Holy **** - this thread makes me want to go back to being a shop based tech again!

I'm surprised to see no one has put peg board on the inside of the lid of any of these carts, so as to clip the most used/quick grab tools to, kind of like this;

But simply fixed, rather than sliding when the lid closes. There's quite a lot of real estate on the inside of the cart lids, so you could get quite a bit on it with a large enough piece of peg board...

PelicanPines · May 18, 2014

Matt_C said:
Holy **** - this thread makes me want to go back to being a shop based tech again!

I'm surprised to see no one has put peg board on the inside of the lid of any of these carts, so as to clip the most used/quick grab tools to, kind of like this;

<snipped image>

But simply fixed, rather than sliding when the lid closes. There's quite a lot of real estate on the inside of the cart lids, so you could get quite a bit on it with a large enough piece of peg board...

****... now I want pegboard... already got the magnet bars... modified em and everything.

That box looks like a box of candy, it's that sweet.

Matt_C · May 18, 2014

Haha, it's the KRA63B. When I first started doing what I do, some 11 years ago now, the resident shop tech had that box (I believe he still does) with a step up box under it, and I fell in love with it. He had his most used "go to" items on it, which is about a dozen or so items, and the drawers took everything else, with just a few more "essentials" in the tote tray in the top.

I'd still love to have that box if I had the room for an opening lid!

cagullett1 · May 18, 2014

PelicanPines said:
The Hoffman shelf is taking a bit longer to paint. I have all the pictures and will post them tomorrow. The shelf was white and the surface was a bit smooth so I topped the shelf with paintable rubber under coat, then painted that red to match the box and the rest. The shelf can hold 150 pounds and is the most solid folding shelf I have come across. It's a bit pricey if you get stuck with retail, it actually costs more than the HF box. I got lucky, I snagged a $40 dollar deal on eBay + $15 shipping. The thing is heavy.

What paint are you using to match the cart?

PelicanPines · May 18, 2014

Apple red rustolium. It's a bit "red'er" than HF. It's a closer match to what I call vintage Craftsman red. But to be honest, I have parts right next to each other in the pictures I posted here about the modification to the side of the cart... and I don't see much of a difference in the photos or in person. The side panel and trim are shaker can painted and it's right next to the HF powder coat... virtually identical.

PelicanPines · May 18, 2014

Matt_C said:
Haha, it's the KRA63B. When I first started doing what I do, some 11 years ago now, the resident shop tech had that box (I believe he still does) with a step up box under it, and I fell in love with it. He had his most used "go to" items on it, which is about a dozen or so items, and the drawers took everything else, with just a few more "essentials" in the tote tray in the top.

I'd still love to have that box if I had the room for an opening lid!

I'm a diehard craftsman 26 inch tower guy... until I saw all the hype on this HF cart. I have fondled SO and Mac boxes and love the quality and visited the HF cart and bought it on the spot.

I would recommend this thing to anybody who needs more storage. I'm moving all my most used stuff, sockets, some wrenches, pliers, punches and safety stuff like my gloves and 3M 95 respirator.

I'm a stickler for detail and trim/finish. I copy what others do... only IMHO, cleaner, better, stronger... :rocker:

cheechi · May 18, 2014

PelicanPines said:
The brace is overkill but the dewalt boxes I store down there are heavy. I modified them with that handle and store all kinds of other stuff in them. Letter punches, hole saw sets, trim router, etc. It holds 7 dewalt boxes perfectly.

I remember when those boxes were more common. Early-mid 90s. Doesn't have to be right now or in this thread, but I'd like to see what you've got in each one.

PelicanPines · May 19, 2014

Progress on modifications...

Got the Snap on hinges installed. I used plastic bushings/spacers to get things lined up. I love the lid at 90 degrees now.

You can see the thick felt bumpers and the car door trim on the lid and on the cart top edge. It closes much quieter now.

The magnetic bars were "modified" from 24 inch down to 20 inch. 2 inches on each side were useless because they were only there to mount the bar. I cut the waste off and cupped each end with tape and poured JB Weld in the ends to simulate an end cap. Also painted the epoxy.

I attached the magnetic bars with 3M molding tape. I have used this tape before and it's seriously sticky.

There is alot of realestate on that lid. I got a few of my other magnetic holders up on the lid also.

In the empty shot... you can see i lined all the screwdriver holes with grommets.

* also in the top you can see the keychain i made from a small screwdriver handle...

paigej · May 19, 2014

Just got around to pulling my welders out of my cart. Finally, I can use this as it was meant to be!

PelicanPines · May 25, 2014

Ok, I'm done.
1. Removed lid activated drawer locks
2. Snap On Hinges
3. Grommets in all the screw driver holes
4. Door Trim all the upper and lower edges including lid
5. Remove US General Badge
6. Cut and enforce bottom shelf to store dewalt metal cases
7. Enclose right panel with trim
8. Install 13 amp power outlet
9. Hoffman 150lb side folding shelf
10. Install hooks and hanging bar on back
11. 20 inch magnetic bars on lid (modified)
12. Matt's Plier Racks !!!

~~ Done ~~ :rocker:

TerryH · May 25, 2014

cagullett1 said:
What paint are you using to match the cart?

Seymour MRO safety red is nearly a perfect match. You can see it on my cart about 176,456 pages back.

TerryH · May 25, 2014

TerryH said:
Finally got time to work on the cart again. Today was the day to put my plan for the prybars and big screwdriver into motion. I considered getting the Sunex prybar side box but after much thought I decided that I would cut out a portion of the area on the handle side of the cart and make my own piece to solve the problem. This cart is specifically for my race trailer so I only need to make room for the 3 biggest prybars and 1 big screwdriver since I only take part of my tools to the track.

I began by laying out where the cut would be. I actually used a 2" hole saw to punch out most of the material and then trimmed it up with my little HF air recip saw. I taped up the inside of the compartment to minimize the paint damage.

Where I needed to start the hole saw there where holes already in the metal so I cut a piece of 1/4" hardboard and put it in the bottom of the compartment so I could drill through that first so the holesaw had a pilot hole.

<a href="http://www.flickr.com/photos/93396776@N06/8500508021/" title="004 by TerryHatfield, on Flickr"><img src="http://farm9.staticflickr.com/8227/8500508021_af35d30cb2.jpg" width="500" height="375" alt="004"></a>

Here's a shot from the bottom of the hole all trimmed up.

<a href="http://www.flickr.com/photos/93396776@N06/8500483049/" title="006 by TerryHatfield, on Flickr"><img src="http://farm9.staticflickr.com/8508/8500483049_06196321c9.jpg" width="500" height="375" alt="006"></a>

I'm using a piece of 2 x 2 x 1/8" angle 18 5/8" long.

<a href="http://www.flickr.com/photos/93396776@N06/8501624972/" title="034 by TerryHatfield, on Flickr"><img src="http://farm9.staticflickr.com/8088/8501624972_415c494b19.jpg" width="500" height="375" alt="034"></a>

I marked and drilled the necessary holes in the angle. Here is the test fit.

<a href="http://www.flickr.com/photos/93396776@N06/8501590468/" title="008 by TerryHatfield, on Flickr"><img src="http://farm9.staticflickr.com/8366/8501590468_5ec1b42204.jpg" width="500" height="375" alt="008"></a>

I sprayed a few coats of Seymour MRO Safety Red on it which is almost a dead on match to the HF color. I used the same to touch up the hole in the box as well.

<a href="http://www.flickr.com/photos/93396776@N06/8500508001/" title="032 by TerryHatfield, on Flickr"><img src="http://farm9.staticflickr.com/8250/8500508001_60abd2d80a.jpg" width="500" height="375" alt="032"></a>

I put some door edge guard on the ends of the hole to make sure that the handles didn't get beat up when the trailer is going down the road.

<a href="http://www.flickr.com/photos/93396776@N06/8500747851/" title="036 by TerryHatfield, on Flickr"><img src="http://farm9.staticflickr.com/8511/8500747851_5ecc3c0c29.jpg" width="500" height="375" alt="036"></a>

Here is the new piece mounted with 2 - 5/16" x 3/4" stainless button heads. It was quite a trick to get the nut on the one on the right. Took me about 30 mintues of fishing through the hole for the prybars with the nut taped to the open end of a 1/2" wrench with vise grips chomped on the box end but I finally got it. It was worth the hassle. I realized after it was too late that I could have just drilled the hole in the angle bigger in that end and just went through that hole. Oh well. Live and learn.

<a href="http://www.flickr.com/photos/93396776@N06/8500747805/" title="041 by TerryHatfield, on Flickr"><img src="http://farm9.staticflickr.com/8091/8500747805_38ea713a2a.jpg" width="500" height="375" alt="041"></a>

Everything fits perfectly under the lid now. I'm super happy with how this turned out!!!

<a href="http://www.flickr.com/photos/93396776@N06/8501855546/" title="039 by TerryHatfield, on Flickr"><img src="http://farm9.staticflickr.com/8247/8501855546_26183b9eed.jpg" width="500" height="375" alt="039"></a>

<a href="http://www.flickr.com/photos/93396776@N06/8500747829/" title="038 by TerryHatfield, on Flickr"><img src="http://farm9.staticflickr.com/8372/8500747829_f37133dd5c.jpg" width="500" height="375" alt="038"></a>

Actually it was on page 23.

PelicanPines · May 25, 2014

I used Rustolium Apple Red. I also used 3m black rubber undercoat (paintable) for the shelf top before hitting it with the Apple Red.

PelicanPines · May 25, 2014

TerryH said:
Seymour MRO safety red is nearly a perfect match. You can see it on my cart about 176,456 pages back.

Even the question was so far back... was excited about my changes... wanted to show the end product. Thought yourz were cool too. Thanks for showing them "again".

TerryH · May 25, 2014

PelicanPines said:
Even the question was so far back... was excited about my changes... wanted to show the end product. Thought yourz were cool too. Thanks for showing them "again".

Your is very cool! Excellent work. :rocker:

alpinewhite · May 25, 2014

PelicanPines said:

What would it look like if you painted the DeWalt boxes red?

Can we see the back of the power strip?

57c · May 25, 2014

I copied what some of you guys did and painted mine with painters touch orange and added a folding shelf. I found I never shut the lid so I converted it to usable space

AndrewV · May 25, 2014

Looka good.
Im going with hammered black, on my ford guy cart.
3/4 of the way done.

stage20 · May 27, 2014

alpinewhite said:
What would it look like if you painted the DeWalt boxes red?

Can we see the back of the power strip?

Look terrible
And that's if the paint sticks.

PelicanPines · May 28, 2014

stage20 said:
Originally Posted by alpinewhite
What would it look like if you painted the DeWalt boxes red?

Can we see the back of the power strip?

The dewalt boxes came to me in tough shape. I masked the "Dewalt" off and painted them flat black (several of them).

Not going to do them red... as Stage20 says... won't look good.

I have various things in the boxes. Two have drills, Hot Glue gun, Heat Gun, Letter/Number Punches & machinest blocks, Hole Saws and the 7th one not on the shelf is my Dewalt Trim Router with all the bases.

The added handle is a square ubolt with added nuts.

MagnumForce · Jun 4, 2014

https://scontent-a-iad.**.fbcdn.net/hphotos-xaf1/t1.0-9/10441246_10153212864494897_1680876348751609464_n.jpg

Well I joined just for this thread, anyway incredibly happy with this thing. I am a maintenance tech in a 100k square foot plant that is a quarter of a mile from the front to my shop in the back. The thing I love is the fact that as I push this thing around the plant it does not bounce all over, the casters that is came with are very good although I wish only one set swiveled. I now keep a set of everything I need for wrenching around the plant in this guy and have all kinds of room for my fab tools in my Craftsman stand up box.

Anyway I am intrigued with some of these shelves you guys have put on yours. How much weight can you put on them? I definitely need to figure out something for the top so I can use that to haul stuff like fans for installation out to the plant. Anyone thought about plasti dipping the lid?

dleonard1122 · Jun 4, 2014

Anyone ever put the inflatable rubber wheels on one? Where I work is a concrete floored shop but often stones and rocks cause me and my cart to come to a screeching halt.

Wondering if these would help or be possible to install.

http://m.harborfreight.com/8-inch-pneumatic-swivel-caster-42485.html

Sent from my iPhone using Tapatalk

PelicanPines · Jun 4, 2014

MagnumForce said:
Anyway I am intrigued with some of these shelves you guys have put on yours. How much weight can you put on them? I definitely need to figure out something for the top so I can use that to haul stuff like fans for installation out to the plant. Anyone thought about plasti dipping the lid?

The Hoffman folding shelf on my cart modification can hold 150 pounds. It's 18 x 18. I picked it up on eBay for $40. They are a little hard to find... at that price.

If I had it to do over... I would apply bed liner to the lid. Instead i installed a rigid foam piece cut to size.

SOCAL399 · Jun 4, 2014

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MagnumForce · Jun 4, 2014

Those casters should install just fine. That said there are some pretty large expansion joints in our plant and this guy rolls across them quite well with no issues.

My only gripe is that all 4 casters swivel. Fine for a small area but not the greatest when you are pushing the thing from one end of the plant to another.

PelicanPines · Jun 4, 2014

MagnumForce said:
Those casters should install just fine. That said there are some pretty large expansion joints in our plant and this guy rolls across them quite well with no issues.

My only gripe is that all 4 casters swivel. Fine for a small area but not the greatest when you are pushing the thing from one end of the plant to another.

For me, the 4 swivels are wonderful for the exact reason you mention. I have to survive with my tools in small garage. I put or will put 4 swivels on everything that rolls. The cart rolls so easily, I have to remember my floor is slanted towards the main door a bit and the thing will gravitate in that direction.

I plan on looking into those soft tires. Thanks for all the great ideas and suggestions for further modifications. Came here for this thread...

C. Smith · Jun 6, 2014

What grit did you sand with? You just sand enough to give it a little something to hold on to?.....Love the color. I've got a lime green viper tool box and am wanting to paint my harbor freight 3 shelf cart I use as a detail cart to match as well as one of these when I pick it up soon. Thanks for the info! And to everyone else. Nice mods so far!

PelicanPines · Jun 6, 2014

120 to 220 grit to prep... use a solvent to wipe everything down after blowing it off. I use a primer before paint when restoring old metal.

Two dollar steak · Jun 6, 2014

Don't mind the mess I'm in the middle of unpacking from a 1k mile move! Top is a "stall mat" for horses bolted down for a non slip work surface, sides are yoga mat strips glued on to keep me from bumping into cars and scratching them.

PelicanPines · Jun 6, 2014

Two dollar steak said:
Don't mind the mess I'm in the middle of unpacking from a 1k mile move! Top is a "stall mat" for horses bolted down for a non slip work surface, sides are yoga mat strips glued on to keep me from bumping into cars and scratching them.

Love the work surface mod. Thanks for the idea...

Lookin4'67Galaxieconv · Jun 6, 2014

MagnumForce said:
https://scontent-a-iad.**.fbcdn.net/hphotos-xaf1/t1.0-9/10441246_10153212864494897_1680876348751609464_n.jpg

You a Michigan State guy? In that case, I can forgive the HF box. :lol_hitti

MN4x4 · Jun 9, 2014

Has anyone added a steel plate or other weight to the bottom of their cart to make it less top-heavy? I worry about mine tipping over if I hit a rock or other 'bump'

MN4x4 · Jun 9, 2014

PelicanPines said:
The electric outlets... I really wanted to be able to plug stuff in on my cart. I figured a power strip would be simple but I wanted something that is all metal. I happened to have an all metal surge protector with a switch and fuse that can handle 12 amps...

I took the box apart and its full of "stuff" you don't want to run a screw into... I considered just attaching the outlet box with 3M tape but that would not have been solid enough from my OCD.

I took off the end panel and drilled holes for "nutserts", I used 2 x 1/4-20tpi. I then realized i had to thread a screw into this and wanted to protect the insides a bit more. I had these red rubber caps from something, so I epoxied them over the nutserts on the inside of the box.

I reassembled the box and attached it to the bottom of that side thing on the cart. I also stuck some 3M tape in there to soften the connection.

I ran the cord under the box and installed hooks on the back of the box, which allowed me to hang an extention cord too.

Nice mods on the cart. I have a TrippLite unit just like that so you've got me thinking.

Your OCD sounds like me - I'm surprised you didn't paint the outlet box to match since you had it apart anyway?

PelicanPines · Jun 9, 2014

MN4x4 said:
Nice mods on the cart. I have a TrippLite unit just like that so you've got me thinking.

Your OCD sounds like me - I'm surprised you didn't paint the outlet box to match since you had it apart anyway?

Trust me... when i had the outlet apart... i said... ok tape this off... tape that off... paint. The original front was too full of stuff I either wanted to see original or would be too much of a pain to "paint around". If I could have gotten the switch out without mauling it...

Modifications to the HF 4 and 5 drawer service carts - what changes have you made?

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