[CAUT] Portable work station completed

[Rob Goodale]

Subject: Re: [CAUT] Portable work station completed


> Just for curiosity, Rob, how much did the cart itself cost? Not the
> lamps, and all the power cords, etc, but just the cart? It's a very
> good looking cart, but just for information, Grainger has a cart that
> looks very similar to yours, 3' x 6', for about $300.
>
> Wim

I need to go through all my receipts but I would guess actual raw materials 
were around $200.00.  Keep in mind, however, that this project was from 
scratch.  I went to a local steel supplier and purchased the steel.  I also 
wound up using some limited steel I already had for certain details 
requiring alternative dimensions.  Other materials included the wheels, the 
pedestal brakes, a 4'x'8 sheet of 3/4" OMB hard board, poplar molding, 
numerous bolts, nuts, and washers, and three cans of spray paint.  The real 
expense was in time.  Designing, cutting the steel, welding and grinding, 
cutting wood and molding, and screwing and bolting everything together.  I'd 
say I have about four full days labor into this.  Less of course the time 
purchasing the materials.  I wanted this to be designed specifically for 
piano servicing from the ground up, not a modified existing product. 
Structurally it is far stronger than any "utility cart" you will ever find. 
The top is hard and perfectly flat for action regulation.  The height is 
designed for comfortable work and to allow the required space for equipment 
and tools below.  As a whole it is quite heavy, I would guess close to 200 
pounds.  Honestly, with the smoothness of the wheels and carefully planned 
placement of the push handle and center of gravity, it roles smooth as silk 
and doesn't feel heavy at all.  Weight was one of my initial concerns but it 
is a non issue.

The electrical was somewhat of an after thought.  I new I wanted a vacuum 
but I wasn't sure how necessary it would be to wire up the whole cart.  In 
it's current configuration all I should ever need to do is plug in the one 
attached cord and everything is ready to go.  I gave the vacuum a long hose 
instead of a long cord to the vacuum.  In other words, the vacuum never 
needs to leave the cart.  When you are finished you just wind up the hose on 
the built-in rack.  The power strip in front provides electricity to any 
power tool you may need, i.e. Dremel, heat gun, whatever.

Now the light was a separate challenge.  I wanted it to be adjustable and 
preferably fluorescent but I also wanted it to easily fold out the way when 
not in use.  After an exhausting search I could not find a ready-made light 
that met this criteria.  My solution required a major modification to an 
under-the-counter fluorescent fixture.  This would foot the bill but it was 
far to flimsy to be reliable.  I disassembled the unit and added internal 
steel reinforcement.  Bolstering the outside housing was the most creative. 
I purchased an aluminum door threshold and cut it down to the length of the 
fixture.  Then I polished it to a shine on the buffer and screwed it to the 
back of the fixture which was the perfect dimension.  The light is now very 
ridged and will withstand quite a beating.  I had to make a swivel bracket 
from scratch using welded steel.  I added two faucet washers to add friction 
so that the angle could be adjusted but stay where you left it.  Adjusting 
the height was another challenge.  I wandered Home Depot searching for ideas 
when an adjustable extension for a paint roller caught my eye.  It was a 
short one, only about two feet when folded and twice that when extended.  It 
was well built made from aluminum and fiber glass.  After cutting it down 
and connecting it to the bracket the whole thing worked out great and was 
very strong.

Soooo... that is a general run down of how it all came together.  Hopefully 
it will be of some inspiration.  I moved it to the university this morning 
and so far it looks like it will work like a dream.

Rob Goodale, RPT
Las Vegas, NV