Modified HF tool cart

[kc-steve]

Hi all, I apologize if this has been done before.

This weekend I picked up the $99/$229 HF tool cart on sale, opened up the box and noticed the instructions say to bolt the casters directly to the bottom sheet metal shelf. Pulling it might be okay but I think pushing it over a rough surface might eventually cause the sheet metal to bend slightly. I'm hobby fabricator that tends to over build my stuff so that just is not an option in my opinion, but the materials alone in the tool cart are worth keeping it so I decided to modify it. The casters aren't the best either. I also didn't like the use of carriage bolts but I'm keeping this project below budget.

Shown in photo #1 are the bottom shelf of maybe 22-24 gauge steel, and an 1/8" thick, 4" wide flat cold-rolled [correction: hot-rolled] steel for the project (I happened to have this laying around). As an after thought, a better solution would have to go buy 3" flat and cut it to the entire width of the cart so that two casters would be supported rather than my current configuration supporting single casters. But this is a budget modification.

Photo #2 is the DeWalt abrasive saw cutting the pieces to size. I also used an angle grinder to round off the edges. Then used a drill press to create the holes, slightly over-sized for the bolts supplied so these plates will fit/match the factory holes.

Photo #3 shows the supporting plates after a coat of self-etching primer and a coat of glossy black.

Photo #4 and #5 shows assembly using the supporting plates. It still isn't quite as strong as I would have personally designed, but then again, I over build stuff and would have never been able to build one for THAT price.

You also might notice a couple of side supporting brackets missing in the last photo. Yes, I didn't thoroughly read through ALL the instructions. I found the side-brackets in one of the drawers after the fact, so now I will have to turn the right-side supports in order to get the support bracket in place now.

Good luck,
Steve

 

[e-tek]

Good idea!

You could also have bought a better cart!!! LOL

 

[Mike B26]

You could also have bought a better cart!!! LOL

Not for $99!!! LOL

 

[kbs2244]

I used a piece of ¾ plywood under the floor and the bigger dia casters they sell.
I also inserted a piece of ¼ plywood as a back and side panel to resist it from racking when being pushed. (I needed longer bolts.)
I think the casters were less than $5.00 each.

I do this kind of thing with a lot of HF stuff.
The overall design can be OK, but sometimes they cut corners with the fasteners, casters, and in the joints.

 

[Dying Fetus]

.....

Shown in photo #1 are the bottom shelf of maybe 22-24 gauge steel, and an 1/8" thick, 4" wide flat cold-rolled steel for the project (I happened to have this laying around)....

......

Nice work, but that looks like hot-rolled to me!

 

[kc-steve]

Nice work, but that looks like hot-rolled to me!

Yup, you're right! I must have had the weather on my mind. I usually work with hot-rolled unless it requires something more resilient to bending etc.

Thanks all,
Steve

 

[kc-steve]

. . .
I think the casters were less than $5.00 each.

I do this kind of thing with a lot of HF stuff.
The overall design can be OK, but sometimes they cut corners with the fasteners, casters, and in the joints.

Those casters that came with the tool cart literally drag compared to other high-dollar casters I've purchased for other projects (and I haven't even put any tools in it yet!). Not so much just spending the extra money as it is just to make sure you get quality casters, because there truly is a big difference and this was my first experience with low-quality casters.

Other projects I've done with quality casters could be pushed with a single finger across a rough surface and continue rolling after the push even when the cart weighed over 100lbs.

The front casters in the welding cart photos below were about $25-30 each from Graingers. I used those on a couple of projects. They called them "hospital grade" casters. But are slicker than snot.

Steve

 

[NUTTSGT]

It looks like you did a good job of reinforcing your new cart.

 

[kc-steve]

Thanks Nutts, I think I will replace the casters eventually, as well as use a different support for two casters mentioned in the first post. Money was my main consideration here though.

Steve