Reply To: Developing a Tri-Level Welding Cart

Reply

Ok, so we redid almost the entire design, and also dropped down to 10ga material. I’m much happier with all the dimensions and the look and utility of the cart – BUT… we made a critical error in the new design. We thinned the material, but we also left all of the slots in the bottom and top layers near the two posts that bear all of the weight of the structure.

If it’s not obvious, the problem with this is that if you push sideways on the upright, it flexes the bottom and top sheets where the slots are! And if we put a lot of weight on the cart, it’s going to be basically floppy.

So, I think we’re getting close but there are a few things we’re considering:

• I think we need to thicken the material back up a bit. At least 3/16″.
• We need to get the slots away from the upright tubes altogether.
• We MAY need to add some additional cross bracing to stiffen it side to side.

I’m hoping that just the first two will be enough for the whole thing to be rigid and strong. I THINK it will, but we have to see. And the fall back would be to add some stiffening across the uprights to make it more of a fully boxed frame.

John P.
Texas Metal Works
Founder