80/20 Machine Kart

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Alas!  Scored a deal vis a vis several vendors (online, local) on 80/20 "10 series" extruded Al and requisite fasteners.  Why?  Quick reaction to assembling a welding kart, AND provide future flexibilty for a CNC milling table.  Down-road options.  Need to be ready to TIG & MIG soonest.   Overall WK dimensions are 18in wide x 24in deep x 36 in height (TBD) w/o casters.  "10 Series" shapes are 1in x 2in.  Note: Al HSS stock was 2x the price point for the 80/20.  However, "they" get you on the fasteners and joining plates.  Aforementioned items accounted for ~ 50% of total cost.A quick GSU drawing of the WK illustrated below.  Basic requirements included a mobile platform containing a Miller Dynasty 200DX w/ Coomate 4 Cooler; MillerMatic 175; and Hypertherm PowerMax 30.  All products fit!  Actually, vertical members are 48in long and the sketch shows 'em at 36".  Extra play available.  Shelves are 18in x 24in HDPE cutting boards.  Inexpensive.  Shelves bonding to Al extrusions via VHB tape and/or Gorilla Glue, and all 1/4-20 fasteners adhered using Loc-Tite 211.  All welding/cutting products will be affixed to HDPE using cut cargo straps.  An allowance for refill of CM4 cooler under consideration.  Ruled out linear slide assemblies due to extra hardware cost.  Probably "muscle-up" the CM4 when req'd to fill the 4gallon chamber.  BTW, had the 4ea, 5in, casters from a previous project.  Notes:  a)`125CF Ar and 80CF C25 cylidners will not be affixed to the WK, but instead attached safely to workshop wall; b) joining plates are anodize Al, colored flat grey and not yellow as depicted.  Not shown is real estate for TIG filler containers (6ea, 36in, RodGuards), TIG Torch / MIG Gun holders, component hooks, and cosmetics (e.g. plastic end caps and bumper guards).  We're gett'n there.  Easy day w/ the remaining 80/20 'drops' and plastic coated wire mesh flooring.80/20 should arrive soonest.  Will jam pix of assembled unit, and proceed directly to welding my 3' x 4' x 1/2" Welding n Fabrication Table. ShaKa! Attached ImagesLast edited by ManoKai; 02-06-2013 at 12:48 AM.Reason: Syntax. Factual Error.
Reply:where you putting the gas bottles?I dont now what the going rate on the 80/20 is, but a 24ft stick of 1 1/2" 11ga. square tubing is $42.. I thought the 80/20 stuff was fairly expensive..Last edited by brucer; 02-05-2013 at 11:52 PM.tackleexperts.comwww.necessityjigs.comhttps://www.facebook.com/groups/mach...dingequipment/
Reply:@ brucer - Check. You're correct.  Paid 2x the cost of raw, including fastener. HOWEVER, able to disassemble and reapropriate the Al extrusions to another effort.  Probably weld an Al WK once Al TIG skills are advanced, and then morph the 80/20 to the CNC effort.IRT your 'where are the bottles housed', they're affixed to the workshop wall. Probably use a 15' whip. Reference: http://weldingweb.com/vbb/showthread.php?t=157761Last edited by ManoKai; 02-06-2013 at 12:12 AM.
Reply:In original post, the statement "Al HSS was 2x the price price point of 80/20" was incorrect and should have read "Al HSS was 1/2x the price point of 80/20."
Reply:As someone who has worked with 80/20 stuff for years a couple of suggestions1 over half the work is assembling the extrusions ...... Planning to disassemble it lattr on seems inefficient2 you don't need those corner plates with 1020 extrusions they are over kill and you will decrease cost 50%3 they have an eBay store with good discounts4 i never have them machine anything as their prices are high all you need is a spiral point tap from mcmastercarr and a drill to bolt those sticks together Hopefully with these suggestions you will save enough money so that you don't feel the need to disassemble it latterGood luck
Reply:@ AW - AwRight. The hardware IS silly expensive.  Understand the joining plates are over-kill and hidden, operator drilled, extensions are GTG. Wanted the design to safely hold DU, liquid Hg, and W bars in the Mad Scientist LaBoratory. Ha! You're right, the Al shapes' E and simple connectors could support the Orbiter' SRBs.Have worked with 80/20 for awhile. Simple, effective, and extensible. Mahalo for your f/b.Last edited by ManoKai; 02-06-2013 at 06:29 AM.Reason: Syntax
Reply:I would reconfigure the bottom of the cart: put your wheels on through-members, and put your uprights on TOP of the same through members. The way you have it the angles are transferring all the loads, which is unnecessary. Does that make sense?Miller XMT304 CC/CVBernard TIG coolerSSC foot pedal"It's a poor craftsman who blames his tewls toles TOOLS" (!^$#% keyboard)
Reply:@ 7A749 - Went with the CM4, as part of the used Miller Dynasty 200DX Package recently acquired.  Package inbound and arriving soonest,  Heard the CM3 is good also.  Never used a cooler before, so it'll be cool (pun intended).  IRT the stack up configuration, that's how it originally was sketched. Ha! Will probably reshuffle the deck as the 80/20 verts are 48" stock.  Room to adjust height. Good call!@ keithwins - thanks. Original design had your recommended config......but altered the stackup when the MIG magically appeared on the scene. Load Transfer 101 ~ you nailed it and I missed it. The WK MK1 Mod 1 will have the verts on TOP of the horizontal members.  Caster config to alter position accordingly.Mahalo brah!Last edited by ManoKai; 02-06-2013 at 05:02 PM.
Reply:@ 7A749 - and the hits just keep on coming.  Great to know!  Will def be integrating an On/Off switch to the CM4.  AND.......ripping signage on the front of the WK that c-l-e-a-r-l-y states:  "FIRST - Power ON Cooler!"  Will hit ya with the .jpgs once the WK is christened.  Shaka!
Reply:@ 7A749 - I would PAY big time to be gett'n some Cold Smoke in a sled or snowboarding.  Winter rocks, and Fall is a close second.  NOVA has been a tad on the chili side.  Send some power our way! It's all good brah!
Reply:Machine Kart "As-Built" @ 90% complete.  Solid, mobile and re-configurable for a future CNC table effort.  Totally satisfied with the 80/20 setup .  Do not foresee any x-y-z stability issues during translation.  DX200 controls at "chin level" and MM175 front panel at "waist level."  Casters install will raise the whole MK ~ 6".  Presently, the Units power cords and TIG/MIG gas hoses restrict kart movement to approximately 8ft.  No worries.  The 25' TIG torch lead and 10' MIG gun lead will easily reach the {semi-permanent} Welding n Fabrication Table that is planned to be positioned ~ 8ft from the Machine Kart.To Be Completed:  Install casters (5", 2 locking, 2 non-locking) w/ Al mounting plates; attach quick-release cargo strapping (thru HDPE and into 80/20 intermediate bracing) to TIG & Plasma Units and Layer 3 & to MIG Unit and Layer 2; Affix RodGuards (36" TIG filler holders) to left side, and hang laminated signage (e.g. Cooler ON before TIG Unit). Attached Images
Reply:@ 7A749 - You're a beacon of bright light.  Pe'ahi.  Yeah, roll'n (pun intend) with 5" hard wheels (phenolic resins, leftovers from the GladiatorWorks Garage Units).  Axle.  Hmm?  Not planning to translate the kart tons, but great idea.  Trying to limit the vertical 'growth' of the kart.  The axle and support structure should be within the 6" vertical plan.  Will have to SketchUp an idea.Time to train with the MM175....vertical inside fillets.  Blaze on!