Rool-a-Round Metal Cutoff Rack

[astroracer]

I have gone out in the shop a half dozen times to clean up my drop pile but, once I get out there and look at all of it, I stop. I have no where to put it that is easily accessible and orderly so I was getting a little frustrated...
I got to thinking about all of the buckets (8 of them!) I am using right now as containers and decided to design a mobile rack to use those buckets.
I measured up a couple of buckets (I have a few different sizes) and modeled up an average size in UG. I had an idea already in my head so I ran with it on the computer. Once the bucket was modeled the rest was easy.
This is a side view. The rack is 24 inches wide.
https://static1.pt-content.com/images/pt/2014/02/ry3D400-1.jpg
Here is a front view. It is 42 inches long and about 48 inches high. Six buckets fit comfortably with room for three more in the middle if I decide to go that way. Right now I am thinking I will make this middle bay a vertical rack for longer drops.
https://static1.pt-content.com/images/pt/2014/02/ry3D400-2.jpg
The buckets set in, and on, 3/4 x 3/4 angle at about a 30deg tip.
https://static1.pt-content.com/images/pt/2014/02/ry3D480-1.jpg
https://static1.pt-content.com/images/pt/2014/02/ry3D480-2.jpg
A close up of the casters. You can see I am also building in a lot of narrow racks for long lengths, whether sheet metal or tubing, Should work very well. I plan to put steel on the bottom and aluminum higher up.
https://static1.pt-content.com/images/pt/2014/02/ry3D480-3.jpg
I did the details last Monday night to build my stock list and ordered the steel Tuesday afternoon. It was in Wednesday so I picked it up and had in the shop by 5.
https://static1.pt-content.com/images/pt/2014/02/ry3D400-3.jpg
Got started on the build this morning about 8. I used some reclaimed 2 x 2 x 1/8 wall tubing to build the lower frame. Spent a few minutes cleaning that up with a flap wheel on my HF angle grinder.
https://static1.pt-content.com/images/pt/2014/02/ry3D400-4.jpg
Lower frame pieces cut and ready to weld
https://static1.pt-content.com/images/pt/2014/02/ry3D400-5.jpg
With the lower frame done we started making the caster brackets. Cut these out of some 1/4" plate. Drilled out to match the caster bolt pattern and put a 45 deg bend on them.
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Welding on the caster plates.
https://static1.pt-content.com/images/pt/2014/02/ry3D400-8.jpg
While Mel was working on the caster plates I was cutting steel for the actual rack part of the build.
Mel drilling the plates.
https://static1.pt-content.com/images/pt/2014/02/ry3D400-9.jpg
Some of the steel I cut. These are 3/4 x 3/4 angle which make up most of the horizontals. The length of the rack proper is 39.75 inches. This let me get three pieces out of a 10' long piece. That little chunk in front is what was left from each piece as "scrap"...
https://static1.pt-content.com/images/pt/2014/02/ry3D400-10.jpg
The vertical pieces going together. These are 1 1/2 x 1 1/2 x 48" long. The rack isn't all that big 24" wide x about 42" long and 51" tall. It will have a lot of storage in it though.
https://static1.pt-content.com/images/pt/2014/02/ry3D400-11.jpg
With the lower frame done, 4 vertical frame done and most of the horizontals cut we will get this thing welded together tomorrow.
https://static1.pt-content.com/images/pt/2014/02/ry3D400-12.jpg
Mark

[bmbrzmn101]

Mark

Great idea! I like the design, but I have a question or suggestion. Could you add a narrow shelf or ledge across the back of the frame to give you a place to put larger pieces of sheet metal without cover the bins on the front. That way if you have a 4x6 piece of 18 or 20 gauge after a project it's out of the way but easily accessed. Just a thought.

Chris

[Thephranc]

Thats brilliant.

[astroracer]

Thanks for the positive responses guys! The rack went together very well. I will be getting it ready for paint in the next few days (evenings I guess).
Chris, I had considered Sheet stock storage when designing it but decided not to worry about it. This is basically just a cut-off and drop organizer and all of my good/new stock is already stored in other spot.

We got it wrapped up today and I think it turned out great!
https://static1.pt-content.com/images/pt/2014/02/ry3D400-13.jpg

https://static1.pt-content.com/images/pt/2014/02/ry3D400-14.jpg

https://static1.pt-content.com/images/pt/2014/02/ry3D480-4.jpg

[astroracer]

Spent a few hours during the week getting the welds cleaned up and the rack wire brushed. Saturday I got a coat of primer on the rack. I brushed it on. Would have went through three cans of spray paint if I had gone that route and I didn't want all of that overspray in the shop.
https://static1.pt-content.com/images/pt/2014/02/ry3D400-19.jpg
I used Rustoleum's clean metal primer. It is white so the red paint should be pretty brite over the top of that.
https://static1.pt-content.com/images/pt/2014/02/ry3D400-20.jpg
While the paint was drying I was working in the house changing out the old hollow core bathroom door with a new oak 3 panel door that I stained and finished a while back. New door frame and all. :)

[astroracer]

Went out this morning and started putting on the red. This is Safety Red I get at Ace hardware. It's oil based and very tough when it dries.
https://static1.pt-content.com/images/pt/2014/02/ry3D400-21.jpg
Got a first coat on most of it and worked on the door install while it was drying.
https://static1.pt-content.com/images/pt/2014/02/ry3D400-22.jpg
Once the rack was mostly dry my wife helped flip it over so I could finish the paint.
https://static1.pt-content.com/images/pt/2014/02/ry3D400-23.jpg
Had a good weekend. Got the rack all painted and that door finally installed. Tomorrow will get the casters installed and I can start sorting thru the pile...
What did you guys do?

[raustinss]

I liked at the drawing you sent...then I sat on the couch lol the Canadian men's and women's curling and hockey....then attempted to watch the rain delay 500
Ryan

[astroracer]

Got the casters bolted up and the shelves cut out of 1/2" OSB tonight. The cart rolls around very nicely. I'll start sorting thru the scrap pile tomorrow. ;D
https://static1.pt-content.com/images/pt/2014/02/ry3D400-24.jpg
I have to get all of my buckets emptied out so I start sorting...
https://static1.pt-content.com/images/pt/2014/02/ry3D400-25.jpg
I still have one shelf to make. The lower one in between the 2 x 2's
https://static1.pt-content.com/images/pt/2014/02/ry3D400-26.jpg
I think this will be a much better solution to storing my cut-offs then piling them on the floor.

[astroracer]

The rack turned out real nice and I finally got the time to get that pile of scraps cleaned up this morning. I started by dumping a bucket on the table so I had something to start sorting into.
https://static1.pt-content.com/images/pt/2014/03/ry3D400-1.jpg
There was a LOT of junk in the buckets. I started tossing all of the unusable stuff into a tote bin. 75% of what I sorted through went into the tote...
https://static1.pt-content.com/images/pt/2014/03/ry3D400-2.jpg
After I had been through four or five buckets this is where I was at. All of the heavy stuff, tubing and anything over an 1/8th inch is in the bottom buckets. Sheet metal up to 14ga is in the middle two and the lighter stuff and aluminum or up top. The drawer unit I had laying around and it seemed like a good storage unit for plate and tube aluminum.
https://static1.pt-content.com/images/pt/2014/03/ry3D400-3.jpg
This a pic of the SECOND tote I filled with stuff to go to the recycler.
https://static1.pt-content.com/images/pt/2014/03/ry3D400-4.jpg
Getting the pile gone.
https://static1.pt-content.com/images/pt/2014/03/ry3D400-5.jpg
With everything cleaned up I am left with this. Everything is in it's place and there is plenty of room for more.
https://static1.pt-content.com/images/pt/2014/03/ry3D400-6.jpg
The back shelves hold a lot of shorts. I am already coming up with some ideas to modify the cart....
https://static1.pt-content.com/images/pt/2014/03/ry3D400-7.jpg
This was good project. I am glad it's done and can be utilized now.