HF 44" twin workbench idea, with adjustable legs

[mtesh73]

hey guys i know this has been covered ad nauseum. thanks to steevo for pioneering this project and all the others that followed suit with their own variations. here is mine:

(2) harbor freight 44" boxes handles removed
(1) global industrial workbench as pictured below $218 # T9A183170
(1) dual sided electrical outlet $50

other option is buy just the legs at $25 each, either black or gray and manufacture a top of your choosing. i am thinking this option because shipping is much cheaper ($100+ less) and i have sheets of 3/4" mdf. one could make the rear 96" stringer out of 2x material or order it for $40.

the only stumbling block i see is the height. the HF box is 40" tall per their sight, i believe others actual measurements have been slightly shorter? the workbench legs adjust to 37" and the separate legs adjust to 36". to correct this i may add a 2x4x30" on top of each leg before mounting the top and maybe the same treatment at the feet of each leg if more clearance is needed. another idea would be to remove the caster entirely and replace with leveling feet and adjust accordingly. this would be a last resort as i think the mobility of wheeling the boxes out would be a plus.

i would also attach a back splash made from mdf, approximately 6" tall. the idea of painting the legs red to match the boxes has crossed my mind as well. northern tool sells a large red locking cabinet that i would like to flank one end of the bench with so i think the red legs might keep things in the same family of colors.

nothing has been constructed yet, but i figured i would put this out there to get some insight, constructive criticism and ideas before fabricating anything.

any input is welcomed. lets hear what everyone has to say.

 

[rsanter]

I guess I do not understand the need for the workbench legs or frame unless you want to be able to roll the boxes out
For me I would just make some feet that can be adjusted in height, bolt them where the casters are, bolt the boxes together and the top to the top of the boxes and you have a stationary workbench

Bob

 

[jim faston]

The height of my older crinkle finish cabinet (including casters) is 39-1/4" to the top of the lip that locates the chest. The box without casters is 33-1/2".

 

[alpinewhite]

I guess I do not understand the need for the workbench legs or frame unless you want to be able to roll the boxes out
For me I would just make some feet that can be adjusted in height, bolt them where the casters are, bolt the boxes together and the top to the top of the boxes and you have a stationary workbench

Bob

Maybe the OP doesn't want the weight of the top and its contents to be bearing down on the cabinets. At least, that was Steevo's premise.

 

[67carl]

As mentioned w/out casters the box is 33 1/2". I took the big casters off and added steel 2" 150# casters from HD, bringing my total height to 36 1/4" (the caster wheels are 2" but the rest of the mechanism adds the additional height).

 

[elronin]

I'm doing the same thing with a 46" Husky soon, I built my bench from 4x4's and a laminated 2" top that I got form an old wood shop from a High school. I'm leaving the casters so I can roll it out and use the top for my miter saw, among other things

 

[usmc_noma]

To keep the casters, you could also add adjustable feet to the bottom of the legs. This way you can add the height and also level the bench. For the top, just use the 3/4" you have on hand and try to find some bowling lane flooring. There's a local dealer here that takes the old flooring, so you may have one there also.

 

[ez-duzit]

Adding a bench top to 40" tall cabinets will make the workbench too tall. I'd remove the casters and simply use the cabinets for the entire support.

 

[mtesh73]

As mentioned w/out casters the box is 33 1/2". I took the big casters off and added steel 2" 150# casters from HD, bringing my total height to 36 1/4" (the caster wheels are 2" but the rest of the mechanism adds the additional height).

now we are talking, i was thinking of "substituting" the casters for something more compact. i think this will work for me.
thanks!!

 

[mtesh73]

To keep the casters, you could also add adjustable feet to the bottom of the legs. This way you can add the height and also level the bench. For the top, just use the 3/4" you have on hand and try to find some bowling lane flooring. There's a local dealer here that takes the old flooring, so you may have one there also.

i like this idea for the bottom, just like steevos bench. i am sure i can source some adjustable feet that will bolt right onto these legs. this is a winner too!
thanks.

 

[taumac]

As mentioned w/out casters the box is 33 1/2". I took the big casters off and added steel 2" 150# casters from HD, bringing my total height to 36 1/4" (the caster wheels are 2" but the rest of the mechanism adds the additional height).

I'm on org casters myself and was thinking of smaller ones myself. Are these ball bearing casters and how easy is it to roll?



Have a good one, Gerard

The 5 Stitches Garage part 1 http://www.garagejournal.com/forum/showthread.php?t=142100

The 5 Stitches Garage part2 http://www.garagejournal.com/forum/showthread.php?t=211899

 

[Jagmandave]

I built my support with wood, and set the boxes right on the wood framework, but I'm rethinking my design as my floor is so unlevel that the boxes are too - it's hard to tell and you won't notice it unless you built it but.....

I'm thinking of buying some 3/4" allthread and nuts and welding up some short adjustable legs with feet for mine. Then the wood framework will surround them but they won't be sitting on it....then I can add a kick panel to keep stuff from rolling under the boxes, and I can accurately level out the boxes as my floor is anything but straight.

or maybe not.......that's a lot of work to correct some minor un-levelishness.

I like the OP's idea of this modular setup, and I'd look for some leveling feet to replace the casters on the toolboxes to keep the top surface from being too high.

 

[ez-duzit]

I built my support with wood, and set the boxes right on the wood framework...
I'm thinking of buying some 3/4" allthread and nuts and welding up some short adjustable legs with feet for mine. Then the wood framework will surround them but they won't be sitting on it...

You needn't go to all that trouble. Simply install T-nuts and inexpensive, adjustable feet.

 

[mtesh73]

As mentioned w/out casters the box is 33 1/2". I took the big casters off and added steel 2" 150# casters from HD, bringing my total height to 36 1/4" (the caster wheels are 2" but the rest of the mechanism adds the additional height).

did you have any weight capacity issues with 2", 150 pound caster versus 5", 300 pound casters. did you utilize the same mounting holes and hardware? did you keep two fixed and two swiveled?

thanks again!!

 

[67carl]

I'm on org casters myself and was thinking of smaller ones myself. Are these ball bearing casters and how easy is it to roll? Have a good one, Gerard

Sorry I didn't respond sooner, I kinda forgot this thread. I can't recall if they are ball bearing and I just tried looking them up on HD website, no luck. I'll go out later and take a look but I just got back from dentist and I'm all hopped up on pain meds. It is easy to roll, though I don't move it much and my floors are smooth.

did you have any weight capacity issues with 2", 150 pound caster versus 5", 300 pound casters. did you utilize the same mounting holes and hardware? did you keep two fixed and two swiveled?

thanks again!!

No issue with weight. I asked around and the consensus is the weight rating is cumulative, meaning 4 casters with 150# rating each means a total capacity of 600#. I figure I can add two more later if needed - one in the front center and one in the back center - that would bump capacity up to 900#. All 4 are swivel casters. The hole patterns for the new casters are much smaller than the originals and required me drilling some new holes. It was a close as there is a channel on the rail and the new holes come close to the edge.

Really not good at descriptions so I got off my *** and took some pics. Turns out they are ball bearing casters. Take a look at the pics and let me know if you guys have any more questions.

 

[67carl]

Caster mounting location...

 

[ez-duzit]

...4 casters with 150# rating each means a total capacity of 600#. I figure I can add two more later if needed - one in the front center and one in the back center - that would bump capacity up to 900#...

No, it won't.

Because of all the vertical sheet metal in the corners, those 4 casters take virtually all the load. Placing a caster under the middle of the drawer opening does virtually nothing to increase load capacity.

 

[67carl]

No, it won't.

Because of all the vertical sheet metal in the corners, those 4 casters take virtually all the load. Placing a caster under the middle of the drawer opening does virtually nothing to increase load capacity.

Good to know, thanks. I guess if It becomes an issue I could install higher load casters.

 

[mtesh73]

Good to know, thanks. I guess if It becomes an issue I could install higher load casters.

Sorry I didn't respond sooner, I kinda forgot this thread. I can't recall if they are ball bearing and I just tried looking them up on HD website, no luck. I'll go out later and take a look but I just got back from dentist and I'm all hopped up on pain meds. It is easy to roll, though I don't move it much and my floors are smooth.



No issue with weight. I asked around and the consensus is the weight rating is cumulative, meaning 4 casters with 150# rating each means a total capacity of 600#. I figure I can add two more later if needed - one in the front center and one in the back center - that would bump capacity up to 900#. All 4 are swivel casters. The hole patterns for the new casters are much smaller than the originals and required me drilling some new holes. It was a close as there is a channel on the rail and the new holes come close to the edge.

Really not good at descriptions so I got off my *** and took some pics. Turns out they are ball bearing casters. Take a look at the pics and let me know if you guys have any more questions.

awesome 67carl, thanks.

i purchased 2 different sets of casters, both 3" with 2xx pound capacities, one set from HF the other from lowes. the set from lowes is offset a bit more so the height is only 3.5" tall instead of 4" tall, the footprint of the lowes caster is more like that of the original 5" (which measures almost 7" tall) caster that is on the box now. so i think i will go with the lowes caster and be able to use the same mounting holes and bolts. there is such a huge difference in the 5" HF that comes on the box and the smaller ones i am considering, however.

another option would be to use the original 5" casters and re-drill the axle hole in the caster body thus lowering the box another 1.25". this would keep the box looking stock, with the same weight capacity as previously mentioned.

 

[redsand187]

I have a couple of those tables. (Well the maple top ones from ULine) I've got them for my shipping stations in my warehouse. I got the accessory casters they make for the table legs, this makes the table ~5-6 taller. I'm 6' tall. It's a perfect height, just below my elbows. I can stand straight up and work at the tables, which is awesome.

I never thought about using these tables for the bench idea, but I can see how it would be a great way to do it, depending on your wants.

I would suggest checking out ULine for these too, they supposedly have warehouses all around the country, to make anywhere just 1 day away if you order before 6pm. They use FedEx freight, which is pretty affordable. I think it cost me like 70 bucks to have each table, with a 36x96" maple butcher block top, and caster set, double pallet that weighed like 350lbs.

Global has always been really expensive for shipping, but I think they are east coast based, and I'm in Washington state, so your results may vary.