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Many years ago mu wife - bless her heart - purchased online a set of draws + tool box on casters combo.
The item arrived damaged so wifey complained and a second item was sent pronto, and we were allowed to keep the first one. WIN!
These toolbox combos are NOT a bunnings stock item. Nor are they made of quality materials. Hence after I filled them with my tools then attempted to wheel them into position, most of the caster mounting points bent / caved in.
So after some time I had a spare day to get this little project done and breath new life into my mobile toolboxes.
Materials
140 x 40mm x 1200 timber.
*marine ply would have been fine
2 x 4pks of casters
8 x 80mm self tapping wood screws with counter-sunk heads
32 x 30mm self tapping wood screws with counter sunk heads
Tools
Ryobi cordless grinder 18v + thin 110mm grinding disc
Ryobi cordless driver with Philips-head driver
small drill bit for pilot holes
Ryobi cordless circular saw
Spirit level
Cordless vac for clean up
HPE
plastic eye glasses
gloves
Steps
Step 1
1. Empty the toolboxes and turn them upside down
Step 2
2. Using the grinder remove the corner caster mounting points
Step 3
3. Using the grinder remove any excess metal in the corner
Step 4
4. Using the circular saw cut the timber to lengths as shown
330mm long and place into position.
Step 5
5. Using the Ryobi cordless drill, drill polit holes 2 in each but end of the timber, 16 in total
Step 6
6. Change bits to the philips-head driver and screw in the 80mm self tappers.16 screws in total
Step 7
7. Dummy-fit the casters on each timber corner and drill 4 pilot holes.
Step 8
8. Using the cordless driver screw in the 30mm sefl tappers.
Step 9
9. Repeat steps 7 & 8 seven more times.
Step 10
10. Turn the tool boxes right side up and check for level using the spirit level.
Hello @grazsmith
Thank you very much for sharing this excellent repair project. The 140x40 should provide excellent support for both the castors and the toolbox itself. Would you happen to have a photo of the toolboxes repaired side by side? I'm sure our members would be keen to see what it looks like.
Again, thank you for sharing this wonderful repair project.
Eric
