Lockers - I need your brains

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Hi everyone.  I picked up two sets of lockers (in the pic) at an auction for a total of $100 !  They are in great shape.  I want to use them as storage in my garage / shop.  I want to put in two more shelves per locker for more storage.  Problem I am coming across is there is little to weld too, or at least in my mind.  The back is sheet and the sides in all is expanded.  I am worried the strength of the expanded will pull in.  I cant tack to the front of the locker as when the door closes it covers any frame part.I guess I am just looking for what you all think is the best way to do this.  Many many many of my projects have me taking short cuts, but I would like to do this one right, but I dont have the experience that most of you do so I welcome any and all input.I wont be storing anything too heavy in there, but I would like to avoid flex.  Thanks in advance. Attached Images
Reply:1/2" square tube from floor to top welded in a couple of places to the expanded metal sides ought to do it. A couple 20' sticks won't run you much, won't take up much of the storage room and should give you all the support you need. Might also run the same from side to side under the shelves so they don't sag. They'll look right, but on the downside you'll probably have to notch out your shelving around them.Lincoln PrecisionTig 275Miller 251Miller DialArc 250Bridgeport millHossfeld bender & diesLogan shaperJet 14 X 40 latheSouth Bend 9" 'C'Hypertherm 900Ellis 3000 band saw21"Royersford ExcelsiorTwo shops, still too many tools.
Reply:Very nice lockers and a pretty good deal.  I think WyoRoy has a good plan.  I would just go about building shelves as if they were just going to be mounted up against a wall or freestanding.  Only difference with yours is they will have a nice expanded metal cage around them to keep everything from sliding off the back or sides when you cram it all full.  You will have a nice storage unit when it's done.  Be sure to show us some pics so we can all be envious.
Reply:Thanks for the input.  I had thought about running some small tube up the sides or even some flat stock but I was thinking it would be a huge waste of material and maybe take away from the look.  Not that that is that big of a concern. And i thought of free standing shelves in there also, I just assumed there is a simple design i am missing.Also, I have a small brake so had thought if I fold a lip at the front and back i could weld the back, put some small square on the side, but was afraid it would still put most of the weight on the expanded.
Reply:The expanded will take a lot of weight as long as it is kept vertical.   Think little girders.   The only problem I can see is getting the paint off so you can weld to the expanded.   Mac
Reply:I'd build angle frames that fit inside and bolt thru the back and expanded metal using large (fender) washers.  Angle legs could be on the bottom to provide secure placement of plywood or metal shelf material as needed/desired.You stated you have a brake so you could use it to build one piece shelves to bolt in the same way.  Bolt-in allows for adjusting as needed to accommodate your gear.Last edited by duaneb55; 06-26-2013 at 11:32 AM.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:I would build a 1" angle iron frame for the shelves to sit on..  built pretty much like the doors are.tackleexperts.comwww.necessityjigs.comhttps://www.facebook.com/groups/mach...dingequipment/
Reply:Just tap the ends of some rod that will fit into the holes in the expanded metal. nut and washer on both sides of the expanded and it's locked in and can't pull in. and will hold your shelf just fine.There are no problems. There are only solutions. It's your duty to determine the right one.Hobart Handler 210Airco 225 Amp MSM Stinger
Reply:The rod going through would be ideal.  However, the holes in the expanded dont line up.  So havent been able to find a clear path to make it level.  That was the first idea.Thinking may go with frames and then put expanded on there just to maintain the appearance, unless someone has a better idea as we go along.The paint is a monster.  Even with ventilation, my garage looked like it snowed red.  Thanks for all the replies so far.
Reply:ok, than just make the shelves and have tabs, two per side, (left right and back) that you can drill through to bolt through the expanded. The tabs can be 2"-3" tall and 1-2" wide to allow for the miss alignment of the expanded metal.There are no problems. There are only solutions. It's your duty to determine the right one.Hobart Handler 210Airco 225 Amp MSM Stinger
Reply:ok, than just make the shelves and have tabs, two per side, (left right and back) that you can drill through to bolt through the expanded. The tabs can be 2"-3" tall and 1-2" wide to allow for the miss alignment of the expanded metal.There ya go,,,, wasnt thinking.  Thats a great idea.
Reply:3/4" Plywood attached to the back wall of the lockers and then adjustable shelves mounted to the plywoodhttp://www.rubbermaid.com/Category/P...od_ID=RP091171Ed Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:Originally Posted by duaneb55I'd build angle frames that fit inside and bolt thru the back and expanded metal using large (fender) washers.  Angle legs could be on the bottom to provide secure placement of plywood or metal shelf material as needed/desired.You stated you have a brake so you could use it to build one piece shelves to bolt in the same way.  Bolt-in allows for adjusting as needed to accommodate your gear.
Reply:Originally Posted by Broccoli13/4" Plywood attached to the back wall of the lockers and then adjustable shelves mounted to the plywoodhttp://www.rubbermaid.com/Category/P...od_ID=RP091171
Reply:Originally Posted by Broccoli13/4" Plywood attached to the back wall of the lockers and then adjustable shelves mounted to the plywoodhttp://www.rubbermaid.com/Category/P...od_ID=RP091171
Reply:I like the rod / brake metal plan since you have the equipment.  Would be pretty easy to slide some round stock through the expanded and brake your metal to fit down over it.  You could weld a washer or piece of flat on one end of your stock to keep it from sliding through and drill & pin it with a washer on the other side.  Or weld some nuts in the ends of some 1/2" pipe and use bolts / fender washers through the expanded into the pipe.  The brake would make your shelves look pretty slick and you could use light gauge but still be strong.
Reply:I looked around the garage for what I had laying around and the cheapest solution after getting everyone's input.  I had a ton of scrap angle iron laying around, so I cut up 3 pieces per shelf (thank god for plasma cutters) and ripped some plywood I had laying around.  Then I sprayed some paint and here are the results.  I have only started putting stuff on the shelves, but I started with a couple thousand rounds of ammo which is about 100 lbs and they didnt blink at the weight.  Since that will be the heaviest thing I will put in there, I am pretty happy.  Not to mention I can lock each locker.  For some compact and sturdy storage for $100, I dont think I could beat it.Thanks for all the suggestions. Attached Images