Help with Fabricating 2 chests together

[Jazzman442]

I have 2 of these Husky tool chests:

http://www.homedepot.com/p/Husky-46...-with-Solid-Wood-Top-Black-7440946R/206839475

I am looking to cut the bottom 2 drawers ( left to right ) off one to make a top box to sit on the other.

What is the best way to cut them out and put the bottom back on shorting the box?

 

[kazlx]

Why, there's probably no less than at least a dozen top boxes that would fit on there and not be a giant waste of time to build....

If for some reason, you're hell bent on doing it. Remove the two drawers, mark out a cut line with painters tape, cut it with a 4.5" cutoff wheel or another means, weld a bottom back on and touch up the paint. But it seems like an awful lot of work for something you could buy that would be just as functional.

 

[Mr_B]

going be a lot of work cut and refinish that to keep good rigidity. could be good if you skilled enough at metal fab, as it all double skinned will be hard plug weld base back in as good as was .
easier/cheaper if not skilled with metal fab to sell one and buy a 41" husky top box
would be more inclined keep them as 2 cabinets as a 90" bench cabinet .

 

[eyeball]

Why?

Why did Columbus sail the ocean blue? Why did Armstrong go to the moon? Because they could.

Why does he want to make this Dr. Frankenstein abomination of a tool box? Because he can!

To Jazzman442 - Bust out the angle grinder, get to work and post a lot of pictures...




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[2oolhound]

Do you want the top box to be removable? If so it needs a bottom. If not you should be able to weld the top to the deck of the bottom to get a nice tower out of it without having to weld in a bottom.

 

[kerrynzl]

I have 2 of these Husky tool chests:

http://www.homedepot.com/p/Husky-46...-with-Solid-Wood-Top-Black-7440946R/206839475

I am looking to cut the bottom 2 drawers ( left to right ) off one to make a top box to sit on the other.

What is the best way to cut them out and put the bottom back on shorting the box?

I've done similar, but I never cut the bottom off one.

I simply removed the wooden bench off the bottom cabinet and unbolted the casters off the top cabinet.
I used strips of 1.6mm aluminium to displace the thickness of the rivnuts that the casters were bolted to, then riveted the 2 together.

I now had some spare casters so I added 2 extra to the bottom cabinet.

I folded up a stainless trim piece to cap the top wooded benchtop, so it looked like a toolbox but I could stack **** on top of it without damaging a sheetmetal top.

I had a 3rd cabinet that I added a backsplash to the benchtop and swapped the casters for machinery feet.[so I could swing off a vice bolted to it]

3 cabinets cleaned up my whole garage.

 

[kerrynzl]

Before and After photos

 

[Mr_B]

^ that looks pretty tidy idea with those 3 cabinets .
OP's idea of chopping 2 big drawers is good as keeps top drawers easier accessed and would look better but will be quite bit of work refit base frame, could make new base from some box and lipped so rests in the lower cabinets recess once wood top removed .

 

[ilovevocs]

That big stack is awesome. How tall are you and how easy is it to use the top drawers.

I feel like I would have to have a step stool!


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[Jazzman442]

This is all very good information. Yes I would like to have more drawers and in one place. I can not find any 46 inch top boxes to match.

kerrynzl that is the look I am after. Great job.

 

[Jazzman442]

I've done similar, but I never cut the bottom off one.

I simply removed the wooden bench off the bottom cabinet and unbolted the casters off the top cabinet.
I used strips of 1.6mm aluminium to displace the thickness of the rivnuts that the casters were bolted to, then riveted the 2 together.

I now had some spare casters so I added 2 extra to the bottom cabinet.

I folded up a stainless trim piece to cap the top wooded benchtop, so it looked like a toolbox but I could stack **** on top of it without damaging a sheetmetal top.

I had a 3rd cabinet that I added a backsplash to the benchtop and swapped the casters for machinery feet.[so I could swing off a vice bolted to it]

3 cabinets cleaned up my whole garage.

What boxes are those?

Looks fantastic.

 

[larry_g]

One way to fit the two together is to find some T shaped material and make a U shaped frame out of that that fits in the space between the two parts. The material will add structure back to the upper box, provide locating edges and hide the cut edge. The T material can be welded, glued, screwed or bolted to the boxes.

http://www.onlinemetals.com/merchan...320000024164&gclid=CNWKm__O4NMCFQxofgod6tcJ5A

Use the above Al material and polish it up for a bit of bling.

lg
no neat sig line

 

[kerrynzl]

That big stack is awesome. How tall are you and how easy is it to use the top drawers.

I feel like I would have to have a step stool!


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I'm 6'2" so height .isn't a problem for me.
I originally wanted a steel lid but the seller sent me a wooden top model.
I folded up a stainless trim to give it the toolbox appearance.

It worked out better that way because I can now stack a few "drop saws' on top of it without damaging it.

The biggest headache so far is I really need to label the drawers.

If you look at the last photo , there is a surplus benchtop that could be cut to make a stepping platform for those that a vertically challenged.

 

[kerrynzl]

This is all very good information. Yes I would like to have more drawers and in one place. I can not find any 46 inch top boxes to match.

kerrynzl that is the look I am after. Great job.

You can never have enough drawers [ or tools]

keep the wooden top , they're made from rubber wood [from the rubber tree] and are very dense and heavy.

Cut the wood back so it is approx 3mm [1/8"] smaller than the chest.
Then fold up a piece of metal to trim it up

My particular toolbox had a 1-1/2" overhang at the rear on the top, to prevent **** from falling down behind it [the front 3 sides were flush]

Photos attached

 

[kerrynzl]

What boxes are those?

Looks fantastic.

I imported them from China while I was up there [a big mistake, because internal shipping is expensive up there]

I could buy some for the same $$ locally [adding shipping, and taxes] and supported a local guy.

they're quite common
https://www.amazon.com/dp/B01067885A/?tag=atomicindus08-20

My biggest issue was finding a cabinet that was approx 18" out from the wall.
Most were too wide.

 

[Jazzman442]

You did a great job on the boxes. It looks awesome. Im getting out the tape measure to see if I can do what you did. My son is 6'3 but I am 5'9' LOL Ill see if he wants the top drawers.

Great job.

 

[kerrynzl]

You did a great job on the boxes. It looks awesome. Im getting out the tape measure to see if I can do what you did. My son is 6'3 but I am 5'9' LOL Ill see if he wants the top drawers.

Great job.

my cabinets total height is 65.75" to the top [ the top edge of the top drawer is 3.75" below that.]

My cabinets were the same height as yours when I started, so you'll end up with the same vertical dimensions.

Now I am going to give you a freebie idea [seeing that you're a short-***]

Because your cabinets are only 46" [vs mine being 72"] you wont need a centre pair of casters underneath.
If you join yours together the same manner as I did , you'll end up with a spare wooden bench.

The ground clearance underneath my cabinets is 7-1/2".
What you need to do is glue/pop-rivet 2 pieces of 2" angle across the cabinet [flange down]between the casters and attach a drawer slide to these.

Trim down the wooden bench and attach it to the drawer slides [Instant pull-out stepping stool]
ADD 4 X fixed Casters to this to take load bearing weight [or you'll tip over your toolbox when you stand on it]

All this requires is a bit of thought with a ruler/tape measure

 

[Jazzman442]

Kerrynzl.. Great information for us Short people LOL Love the tip that is a fantastic idea..