I do promotions. I need a rolling cart I can use as my portable base of operations. I just basically need a flat top, some places to stick flyers, an enter-to-win ballot box type thing, and storage for all the free swag. Maybe I’ll put a battery and power inverter on it. Maybe I’ll wire it to play music somehow. I dunno. I’d like to have interchangeable side panels, so I can change them without repainting the whole thing. That’s all fun stuff. It just needs to close up so people don’t walk off with all the free stuff if I have to step away.
I’m not sure how to build the skeleton. I’m basically thinking about nailing together some 2×4’s, sticking some casters on the bottom, and a melamine top. For the sides, maybe sheet rock or plywood or OSB or peg board or maybe even fabric. But I want to make this thing kind of sturdy so I can push it from the top without all the nails popping out. How could I form the joints for the 2×4’s? Would I need some type of cross braces? Should I use some of those metal connectors they have for building decks? Screws? Glue? I dunno. I don’t have any experience in designing something like this.
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Milwaukee has a real nifty cart that is expanable..
it may suit yur needs....
Milwaukee tool/work carts...
Sams has several versins of food service carts too...
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Thanks for the input.
Industrial Work Cart with Locking Cabinet? Yeah. That's exactly what I need... except it looks like an industrial work cart with locking cabinet. :) It would need a lot of cosmetic surgery.
If I buy something, I'll get one of the cheap rubbermaid ones. But I thought stick-building something would give me more of the look I'm going for and it will be a fun challenge.
Or if I do use a plastic cart as the skeleton, how could I screw the melamine into that? Maybe I could use velcro or magnets to hold the sides on...
Edited 7/9/2007 12:59 am ET by InStock
Screw the cart to the decorative ''skin'' from the inside. Build the box, slip it over the cart and fasten.
You should be able to make up a lighter box using moderate thickness plywood reinforced with corner blocks. Remember you'll be lifting this thing into your ride, up over curbs etc.A great place for Information, Comraderie, and a sucker punch.
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I am sure you are re-inventing the wheel here to some degree. I remember from the last JLC live, I was still in the display hall/floor area when a lot of the sales reps were packing up and hauling off.I remember seeing some things that were basically a good size box that folded open, had hard sides - black with a faux leather sureface, and AL rounded corners, and built into it some wheels like those airport suitcases and hand truck collapsing handles too.You just gotta find who makes the things.
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I'd start with metal.... look at sams ... maybe a housekeeping cart... pretty sure you can buy a whole cart for less than you'd spend on good casters/wheels
p
There are a few different kinds of tool boxes on a collapsible hand truck type frame at HD. Maybe one of those would work for you
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Taunton University of Knowledge FHB Campus at Breaktime.
where ...
Excellence is its own reward!
I'd use half-lap joints on the 2x4's. 2x4 frame and signboard (MDO) for the infill panels. If you use plywood of MDO, you don't need cross bracing to keep it from racking (being pushed out of square). You may be able to, as another poster said, use blocking on edges and corners of the plywood to fasten it together. (Instead of full frame of 2x4's which can get heavy.) I have made boxes using sandwiches of 1/8" panelling with Styrofoam "filling" by gluing the foam to the panelling and using 2x2 edges so panels can be screwed together. Something like that may work, but is still heavier than you might imagine.
May be more than what you're looking to do, but we just did something similar on a larger scale. The city commissioned us to design/build an outdoor kiosk with computer equipment inside. The construction was pretty simple. Aluminum frame (fabricated by a welding shop), with stained plywood and polycarb panels bolted over it. An 'industrial' look was part of the design, so a mill finish was fine. Welds did not need to be ground smooth, and fasteners were purposely exposed. Casters are mounted to the bottom so it can be rolled around.
If you can design the skeleton, maybe have a shop put it together. Then you can do whatever you want with it (sorry in advance about the file size).
As you might guess, there is an amazing variety of carts manufactured, costing anywhere from $40 (Harbor Freight, basic metal) to over $800 (Milwaukee).
There is not much correlation between the price you pay, and the quality of the cart. Some fairly expensive ones ... Edsal and Rubbermade are two that have disappointed me ... are pretty cheesy.
My Edsal failed in the same manner that most home-built wood carts fail: move it around a few times, and the joints loosen up, and you can hear the dumpster calling :( The Rubbermade, in a similar manner, twisted as the result of being moved while overloaded; the load rating of the drawers is wildly optimistic.
If you're going to make your own, the rigidity of the frame is key. I suggest a frame made of 2x2's, connected with Simpson RTC-22 connectors.
If using metal, rectangular tubing, approximately 3/4 x 1 1/2", will make a very stiff, lightweight frame.
The first thing you need to do is mot closely define your needs. How large need it be? Does it need to come apart for transport? How much weight will it need to carry? On how good of a floor will it be used? Just how will it be loaded and transported?
Now, that said ... I have found great utility in simply mounting a wood box to a 2-wheel cart.
Cart #1 had a box approximately 2x2x4' tall. The front was split, so as to open as 'double doors.' Inside, there were several simple shelves, simple pieces of 1/4" luan, that slid in grooved uprights.
Cart #2 had a custom made, wheeled frame, that readily detached. The frame was used to tow this cabinet behind a bicycle. The cabinet itself was 30" wide, 40" tall, and only 12" deep. It was customized to hold tools, and to function as a work center.
Cart #3 is an on-going project, based upon a box 24" wide, 18" deep, and 48" tall. These boxes are made to easily slide onto the cart, and are optimized to different uses. One is for tools, another for parts, a third as a work station.
SIZE is probably the most important single criteria. Too small, and it won't be useful. Too large, and you'll have a hard time in elevators and narrow aisles.
Instock,
You might try looking online for an extruded aluminum profile available from 80/20 or several others. These are structural aluminum sections with slots that hold t-nuts and can be bolted together with machine screws and plates to form extremely rigid structures. In a former life I used this material to build many machines, tables, carts and such.
http://www.8020.net/