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  • Steel Rack Extension

    I have a couple of heavy-duty racks that I use to store steel. One of the racks sticks through a hole in the wall which limits the maximum height of the rack. I decided to cut off the unusable top of the rack and use it to extend the height of a second rack, located in my addition, where there is more head room.

    1. Old rack
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    After cutting off the four corner columns, I ground off the cross brace. The original cross brace was 18 inches long and the new one needed to be 24” long. Also, the new brace needed to have a higher section because I wanted to rest some metal directly on the cross brace.

    2. Grinding off cross brace
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    I selected a 1/16” wall 1-1/2” square tube for the new cross brace. I used my Fireball angles and magnetic blocks to fixture the frame in place. I find the Fireball tools to be very useful.

    3. Fixturing with Fireball Tools
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    The next step was to tack weld the cross brace in place. I tack welded all four sides of each tube before I welded it out. I used my Lincoln LE31 MP welder which is 140 amp 120 volt multi-process welder. I used .030” wire, which was in the welder, but I should have switched to .025” wire, because the thickness of the columns was only about .035” (Not including the paint).

    4. Tack welds
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    Next, I welded it the frame. I positioned the frame so that the heavier 1/16” wall tube was on the top, to help prevent burning through the thinner metal of the columns on the bottom.

    5. Weld-1
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    Miller Thunderbolt
    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Lincoln LE 31 MP
    Lincoln 210 MP
    Clausing/Colchester 15" Lathe
    16" DuAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport

  • #2
    6. Weld-2
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    Here are two pictures of the extension frames on top of the existing steel rack.

    7. Frame-1
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    8. Frame-2
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    I blind riveted tabs on the end of the extensions to align the extensions with the existing columns of the steel rack. I was planning on welding the extensions, but it was so rigid that I didn’t bother welding them.

    9. Blind rivet splice
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    And here it is all done.

    10. All done
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    -Don
    Miller Thunderbolt
    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Lincoln LE 31 MP
    Lincoln 210 MP
    Clausing/Colchester 15" Lathe
    16" DuAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport

    Comment


    • #3
      I like those big squares, Don. When you’re done, you can send them to me.

      Comment


      • #4
        Originally posted by ryanjones2150 View Post
        I like those big squares, Don. When you’re done, you can send them to me.
        I really like all of the Fireball products.
        I would like to purchase the next larger size square as well.
        it will have to wait, because I just bought a precision 8” Chuck for my lathe.

        -Don
        Last edited by Don52; 07-29-2021, 12:47 PM.
        Miller Thunderbolt
        Smith Oxyacetylene Torch
        Miller Dynasty 200DX
        Lincoln SP-250 MIG Welder
        Lincoln LE 31 MP
        Lincoln 210 MP
        Clausing/Colchester 15" Lathe
        16" DuAll Saw
        15" Drill Press
        7" x 9" Swivel Head Horizontal Band Saw
        20 Ton Arbor Press
        Bridgeport

        Comment


        • #5
          Click image for larger version

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          Comment


          • #6
            Don, if you look can see a similar deal on top of my big one. It isnt as custom as yours, was a whiz deal.

            Comment


            • #7
              Originally posted by Sberry View Post
              Don, if you look can see a similar deal on top of my big one. It isnt as custom as yours, was a whiz deal.
              I love your metal collection. I am jealous.

              -Don
              Miller Thunderbolt
              Smith Oxyacetylene Torch
              Miller Dynasty 200DX
              Lincoln SP-250 MIG Welder
              Lincoln LE 31 MP
              Lincoln 210 MP
              Clausing/Colchester 15" Lathe
              16" DuAll Saw
              15" Drill Press
              7" x 9" Swivel Head Horizontal Band Saw
              20 Ton Arbor Press
              Bridgeport

              Comment


              • #8
                Don. I collect it and process so to speak
                trim it to store. I rarely buy steel and haven't for long time. I find so much so close, even holes in it.
                we were installing/working in a roadside ditch the other day and find a piece of 1/4 2 1/2 x 2 1/2 angle near new about 5 ft long must forgot to finish weld in on a county truck.

                Comment

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