Building a hutch for my toolbox with free materials

[HightechRedneck]

Well as most of you guys know I recently purchased a 72" Matco 4s toolbox for a decent price.

http://i387.photobucket.com/albums/oo313/Dustin_Fletcher/ab15c01c.jpg

I went online searching for a hutch for the box being I want something to place chargers and larger items in. I came back empty handed so I'm not sure if they even make one.

So I decided to go look at a few snapon ones and I just can't justify spending more than $500 for a sheet of metal some uprights, along with peg board, and paint. Dad said why not build one. So, I said screw it and why not try. I'm 23 and have done some fabricating in the past and enjoy working with metal so game on. I will be posting pics as I go. Give me honest opinions of what you think.

Day 1 - gathered material and start building frame work.

http://i387.photobucket.com/albums/oo313/Dustin_Fletcher/4d0f084b.jpg

http://i387.photobucket.com/albums/oo313/Dustin_Fletcher/00a4a909.jpg

http://i387.photobucket.com/albums/oo313/Dustin_Fletcher/3e0f1ecf.jpg

http://i387.photobucket.com/albums/oo313/Dustin_Fletcher/805ba994.jpg

Remember this is all free scrap metal I have laying around. Prior to painting I will be sanding and wire wheeling everything to a raw state.

[AHall]

I like your enthusiasm. Couple guys at work have done this and several have built additions to the road call boxes.

[HightechRedneck]

I like your enthusiasm. Couple guys at work have done this and several have built additions to the road call boxes.

Thanks Adam!

The only thing I'm not positive on is a door. This top is almost 30" tall and isn't 30" deep. Dad was thinking a folding door that swings around the side but I want to do an up and down door (either roll up or slide up panel) currently weighing the options.

Did their boxes turn out pretty good? I know I'm over killing this one with this material but I might as well build it to last.

[cummin try me]

Looks good so far. i agree with you that Snap-on, etc. want quite a pretty penny for their hutches and if I wanted one I would just build it. Just a tip, I would wire wheel everything before it gets welded in. That way you will be able to get to all the areas of the steel before they become inaccessible. How tall will it be? Another option for the lid could be one that swings up and out using gas struts. The only things you would have to worry about is if it's tall enough to clear your head and lighting. You could always put a light inside the hutch to get around that though.

[HightechRedneck]

It's 30" tall. I'm 6'1 so height was definately a huge priority. Only issue I see with it hanging out or so like others is if I have a taller co-worker I don't want them to smash their head on it. It will have LED strip lights on inside of it if I can locate some 110v units instead or 12v. Planning on rocker switches for power to everything.

I was debating a half fold long wise then up and slide in for the final motion. I think it's a better option for this instance but honestly I won't know till I get to that ordeal.

Thanks

[HightechRedneck]

Update!

Everything is tacked together and final measurements are 72" wide 23" deep with 30" tall. The door I'm going to do will be a flip out and up then rest at an angle upwards so its out of the way. Very simple solution to a complex question.

Pics:
http://i387.photobucket.com/albums/oo313/Dustin_Fletcher/d9dd4b9b.jpg

http://i387.photobucket.com/albums/oo313/Dustin_Fletcher/f807ff91.jpg

http://i387.photobucket.com/albums/oo313/Dustin_Fletcher/36603401.jpg

http://i387.photobucket.com/albums/oo313/Dustin_Fletcher/ddb571bf.jpg

I worked on it for a few hours tonight. Everything will be welded tomorrow and I should be ready to wrap sheet metal around it shortly.

[bosshogg]

Here's what I did on top of my snap-on. I laid a sheet of plywood down on the top of the box and then screwed the uprights to it from underneath. I also sandwiched the factory rubber mat in between.
I got a 12V DC converter from radio shack and powered the sony head unit with it. I had the speakers laying around not being used so I just set them on top of the box. The light is a cordless underhood light but I hang it up there for storage and turn it on when needed.

[HightechRedneck]

Nice!

I wonder what Ohio CAT would say if I had a stereo and a flip down tv in my toolbox.

LOL

[HightechRedneck]

Well I worked on it for a few more hours tonight. The whole frame work is done with. Welded solid and just needing to grind a little more on edges. Also learned I can't weld a nice head to save my life though I was using a new welder I hadnt used before.

http://i387.photobucket.com/albums/oo313/Dustin_Fletcher/5b8128db.jpg

http://i387.photobucket.com/albums/oo313/Dustin_Fletcher/9c8f4f33.jpg

http://i387.photobucket.com/albums/oo313/Dustin_Fletcher/cf5031c2.jpg

http://i387.photobucket.com/albums/oo313/Dustin_Fletcher/b476515e.jpg

Final measurements are 74" tall over all, 72" wide. Wrapping in sheet metal in a couple days then painting blue to match and on the door will have a custom vinyl work done. I did buy a 6' long hinge today for the door for $6.00 so that's my only expense this far. I will have to buy paint and 2 sheets of sheet metal. Can't wait to get it done.

[LReiff]

Put a florescent light fixture up inside that thing! You'll thank me later.

[HightechRedneck]

I have a 4 foot one lying here but I was thinking about a 6ft strip of LED lights on an angle. Reason being is cheap, lasts, and I can convert to 12v so I can do a potential stereo in the future.

I also have a 4ft T5 light fixture but they are stupid bright and i don't know if I want something like that. It definately will have a strip mounted on the inside panel and lights.

[turbojoe]

Put a florescent light fixture up inside that thing! You'll thank me later.

If you do, you might want to be careful how you lift things and swing them around in there because if you hit one, they make a real mess:bang.

Joe

[Red Sleeper]

How does it attach to the box?

[LReiff]

I have two of these (http://images10.newegg.com/NeweggImage/ProductImageCompressAll300/A05W_1_20110622_3110570.jpg), but in triple bulb configuration mounted under my hutch. If I do it over I'll go with LED, the halogen bulbs are expensive and they get hot.

[HightechRedneck]

LED it is then.

Right now attachment is going to be just sitting on top. The bottom plate is 1/8 thick. If needin to fasten down I will utilize the holes in the box on top and bolt it down. I don't think it will be necessary though. Only time will tell though.

Sheet metal is hopefully getting cut tomorrow for it and I will be able to get a full box ready. Frame work is going to get brushed black, work base is getting a truck bed coating, outside will be matco blue to match and the inside will be white to reflect the light better.