Good Afternoon,
I am designing layout #3. I want to go 5.5'x22. I want to get it up on casters so I can pull it out from the wall to work on it. Most big sturdy casters are nearly 4" wide, and my only lumber options seem to be sandwiched 2x4's or treated fence posts. I don't really want to sandwich 2'4's and the treated posts seem ridiculously heavy. What other options might be out there? Thanks!
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Just a thought, but what about two 2"x4"'s screwed together in an 'L' shape for the legs. You could cut a square block of 2"x6" (5-1/2"x5-1/2"), fasten that to the bottom of the 2"x4"'s in the 'L' configuration and bolt the casters to that. Should be plenty of room for the 4" square casters with a little left over so you don't split the wood.
If you have access to welding a 2x4 sleeve could be tacked to the plate. Then the excess trimmed. The plates bearing track is the variable. Race size, and it might warp if the welder isn't experienced, are two "no" darts to throw at the idea.
Someone does/ or has produced 2x4 sleeved wheels. I've seen them on a coin op tech's benches before. Keep looking!?!?
Depending on the weight, you might be able to get away with using PVC fence posts. You'd need to insert a 3 1/2" block of "4x4" post into the bottom and top and secure them with some heavy screws, but on a short section (less than 4 feet) you shouldn't get a lot of flexing.
With the legs being on wheels you are going to need at least some additional bracing beyond what 2x4's sitting on the floor requires. without a firm anchor the legs are going to want to move about and bend to the sides if only attached at the top.
I bring this up because what I would do in this case is to attach the legs to a flat 2x6 (5.5 inches should give those 4" wheel plates a solid mount.) along the bottom to connect all the legs, then you could attach the wheels anywhere along that "base plate". May be able to get away with less wheels that way as well. In effect the legs would be framed like a stud wall, and doing so would lock them together in a way that would keep them from flexing much. (You may want to add a diagonal brace in each direction to lock everything perfectly in place.)
Look into double wheeled casters that have a post on them. Drill an appropriate hole in the end of the leg, insert the receiver and then snap in the post of the caster. As above, some additional bracing for the legs may be needed. There is always Mianne Benchwork.
Take a look a BrianEso's solution.
The casters are a 3 wheel dolly from Home Depot.
The leg is not the issue, it's the bracing of the leg to prevent the lateral forces from ripping it out of it's mounting. Brian framed around the bottom to solve that issue.
Diagonal supports, similar to l-girder style, would work. I have also looked at some brackets meant for a different application to support the top of the 2 x 4. We have not tested it yet on an 11 x 17 3 level layout that we are working on. It may have to be moved when it is finally assembled at it's permanent location. I attached this laterally to the frame cross-member to keep the vertical 2 x 4 from twisting. We haven't put the casters on yet as other work needs to completed. You cannot twist or move the leg.(LOL, if you look at the relocation move in the shop area, we jacked it up on moving dollies, chairs and a work shop cart to drag it 100'.)
Lastly, you really need to be on a hard smooth floor. I don't think you'll find a solution for a carpeted floor.
I hope that gives you some ideas.
I strongly echo what "moonman" posted...
..."Lastly, you really need to be on a hard smooth floor. I don't think you'll find a solution for a carpeted floor"...
And one more thing...based on being a "store fixture jockey" for many of my 36+ years working for a major national retailer...
..."the larger the diameter the caster wheel the better"...
Howard...
Most of the Fort Pitt High Railers modules are 37.5" X 72" each with two removable leg sets. Seems to work well for a portable system. Framed with 1"X 4" good quality sheeting board, the deck is 3/16" luan board. Exterior framing is double with the addition of a stain display board on either side.
Back side of a module.
Leg sets stacked on top of stored modules. The legs are 1 1/2" X 1 1/2"
Note the legs, and clamp boards on this much larger "Y" module.
Leveling system. 5/16" eye bolts.
This turntable module has 1/2" EMT, Electrical Metalic Tubing, used as leg cross braces for stability. Silver pipe behind the power supply.
Take a look at globalindustrial.com I built a 5 X 9 layout using these support legs and frame. I built the top part of the layout using L girder design and just centered it on top of the frame.
Workbench Legs with Outlet Knockouts Available in Fixed Heights of 28" or 32" or an Adjustable Height of 27-7/8" to 35-3/8". Made of 13 gauge steel. All legs feature removable duplex knockouts for installation of hard wired electrical outlet. Legs feature pre-drilled holes for tops, stringers, and lower shelf attachment. Legs can be mounted to bench tops 30" or 36" deep. Priced Per Leg $29 to $32
On carpet, those large 5" plastic "furniture moving disks" at the local dept. store work very well for sliding. You need good leg bracing, they aren't wheels, but they work well
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