After the steel components for the display wall had been installed, I was asked to design a rolling ladder for this display wall, to allow staff to reach the top shelves. After the initial design drawings had been approved last week, I ordered material and started to fabricate the brackets that will hold the track in place. Because of the length and height of the wall, I wanted these brackets to allow for some adjustability to ensure that the track will be mounted level and straight. Here are some pictures of fabricating the track brackets. This is the work of several days!
Here re the wheels that will be used for this project. The 6″ rubber wheels are for the contact of the ladder to the floor, the 5″ cast iron track wheels are for the top of the track, and the 3″ rubber wheels are for below the track.
I started to cut some 1 1/4″ thick wall square tubing for the lower portion of the track brackets, and started to drill the mounting holes with my magnetic drill. I used the little stops for consistent spacing of the two holes.
Here is a closeup drilling the hole in front.
Here is a closeup of drilling the back hole.
Marking the mounting holes for the adjustable top portion of the track brackets.
Drilling a 1/2″ pilot hole through the tube.
Following with a 3/4″ hole.
I got these 1/2″ thread connector nuts.
I drove the nuts through the 3/4″ holes and they fit very tight.
All the excess length was cut off on the bandsaw.
All ground nice and flush.
All welded and finish ground.
I made some mounting plates similar to the ones I used for the shelf standards.
Welding them in place all the way around.
Here I’m starting to mill holes into the top portion of the track brackets.
This will alllow a 1″ up/down adjustment.
All done!
Some top caps for the 1 1/2″ square tubes.
My “3rd hand” helping me as I’m welding the caps on.
All cleaned up!
Next step was the layout of the track plates in CAD, and then the cutting of all the components out of 1/4″ plate.
All the parts are cleaned up and ready for welding.
Here is the setup to weld the top plate in place. I just got these Fireball welding squares, and they worked perfectly in this application!
Another picture of the setup to tack weld the plate to the tube.
Right next to it I set up my upright fixture for finish welding the plate to the tube.
The top view of all the top plates.
The view from below.
Next step was welding the top braces in place.
Another view.
All done! Onto the next!
After consulting with the powder coating company in regards to the finish thickness, I cut two pieces of 3/16″ flat stock and added tape to get to the final thickness of the track.
I placed the two pieces between the top and bottom plate for consistent spacing.
I clamped the pieces together for tack welding.
Finish welding as before.
Adding the bottom brace.
I added a top tab to the tube in case it is necessary for fastening to the wall.
Again the welding sqares made it easy to get a consistent setup.
A closeup of the weld.
All the adjustable tops are done.
Another view.
A 3″x3″ angle witth 3/16″ wall thickness will serve as a track for the ladder. Here I made a mock-up piece to show the 1″ adjustability incorporated into the top plates. All the way out!
All the way in!
Again the up/down adjustment of the track brackets.
And at last a picture of the levelers to ensure plumb installation to an old and inconsistent brick wall.
