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In this video I (Mike) will show how to takes regular 10″ Pneumatic Caster Wheels and customize it to what we call the Triple Threat Caster! The whole idea behind this style of wheel is not just for the looks, although they do look amazingly TOUGH ….. It has a function.
Have you ever over loaded air wheels before??? I have… While using a flat bed cart to simply move a boat trailer, I placed the tongue of the trailer on the cart which has 10″ pneumatic wheels and even though it had 35psi in each of the wheels the two wheels the tongue was over was compressed to the point where it was difficult to push the cart & boat trailer around and from that, an idea was formed.
Now fast forward one year. While I was building the new roll away tool cart from the drawer cabinet I scored, I knew it would need to handle a lot of weight, be capable of going off road & function like a regular roll away would so I figured what better way is there to make the wheels even more heavy duty, well… ADD MORE WHEELS!!! Similar to the big rig trailers that move heavy equipment & have 10 wheels across the entire back.
I went to Harbor Freight & purchased 4 10″ pneumatic casters, 2 swivel & 2 ridged. Then began the process of making my idea a reality. I wasn’t sure how the swivel casters would work out (because the wheels are off set & they swivel, they do have their limits) but over all they perform wonderfully & I definitely would do it again. Now all I need to do is modify my flat cart, just the back 2 ridged wheels & only add 1 wheel to the center of each…Hm mm, I shall call that the DOUBLE THREAT!!.
The Disclaimer:::::::::
1.) Remember this is a modified caster. The triple threat caster is technically capable of carrying a larger load then the 300lbs these wheels are rated at by the manufacturer. With that said the caster it self does have its limits. While the wheels are stacked up, side by side with 35psi in each they can most likely handle 900lbs of weight per corner the METAL on the caster chassis (frame) was NOT designed to handle such a load. So it is only as strong as the metal the wheel axle attaches to. Also the rigid caster will be much more capable of handling heavier loads as opposed to the swivel casters which already has a strong angle & bearing that’s designed to make it swivel in the first place.
2.) The casters were designed (by the manufacturer) to have the wheels centered between the chassis of the caster frame. Not offset 3″. So it’s possible while using the customised casters to run into a curb, rock, rut, anything large enough to stop the wheels while under way & cause severe damage to the metal by twisting or throwing the metal out of alignment. So I recommend using these custom casters on a relatively flat surface & simply be aware of their limits. Okay, got it? Good!!!
Now the process of describing in further details how to do this in case you missed anything. First buy the goods. No need to modify the swivel casters unless you simply like the looks. If you do plan on doing this to all 4 casters all you need for the new axle is 2 36″ rods. I got mine from the hardware store ($10 each) One of the axle rods will produce 3 10″ long axles & the remaining 5.5″-6″ can be what you use to transform the axle back to stock. The other 36″ rod will produce one more 10″ axle & the other 3 remaining 6″ pieces to make it stock again if you ever wish to do so. Remember once you drill out the metal on the chassis the bolt will be worthless but save that anyway for what ever comes up.I suppose it is possible to reuse the bolt with a washer & a fitting that would fill the material that was removed but since I had extra axle lengths this is what I did…
Pinch / clamp the metal opening on the caster to 3 7/8 before the new caster axle is drilled Lots of grease. Please note that in order to maintain the tire pressure & refill with air the triple threat caster will need to be taken apart while assembling the wheels always put the valve stem facing outward.
Wheel alignment is important with the rigid casters. Be sure the axles are in line with one another to get even, less restrictive momentum. If they are not properly aligned this will cause excessive wear on the tire tread thus needing premature replacement. I do somewhat cover this in the last video while building the toolbox rollaway.
Have at it. This is a easy project, $100-$200 depending how you work it. I paid about 15 for each caster, 4 for the extra 8 wheels each, 4 for the cotter pins all with 20% off coupons at harbor freight. I also paid 18 total for the 2 36″ long axles + 20 for the 5/8 drill bit. Comment or questions welcomed!