The latest on "J2D2" Ballast box design

[Dan22]

I posted before that I was going to build a ballast box out of a 40 gallon water tank and various scrap metal I had laying around. Well, I have some progress designs and construction pix for you to enjoy.

The first is the initial design which got modified in part due to some great suggestions from some members. I got the casters free so I went with solid and not pneumatic tires.

Next is the modified design with casters, proper locations of the hitch points, and I added some loops for stashing a shovel or splitting maul.

The next thing I may add will be a scabbard for the chain saw perhaps. Just having fun figuring it out.

Lastly are the pix of the actual unit under construction. It is not filled yet with concrete. Bottom dolly frame is removable, and I plan on filling the bottom concave cavity with concrete too. I welded some hangers in there to hold the concrete in place.

I will send more pix as it gets completed.

 

[Dan22]

Well the paint is cured and decals attached. Thought it was time to show the final product. Turned out to weigh about 750 lbs. Squats the tires a bit when it picks up. Very easy to connect with the 5" casters to roll on. Lifted ground clearance is good as I put the lower pins down low enough. "J2D2" is my combination of R2D2 and JD, in case you wondered.

I have yet to tow anything with it but it will do good for light trailer towing. I wont put anything more than 500 lbs or so on the hitch.

I left the top pipe plugs out to let the concrete at least attempt to dry out. I did not want trapped water to eventually freeze and bulge it out. Time will tell if it will ever dry inside.

Tool pockets fit just right too. No scratching the paint.

My wife wonders why I keep scrap metal (old broken water heater tanks) and this and that around. I figure I will use it some day. Well, this is that day.

 

[Dan22]

Here is a close up of the "name".

I may put a slow sign decal on it too.

Dan

 

[Zephrant]

Looks nice, but I think you missed the boat by not hiding a small keg in there, and installing a tap.... for after-work use of course.

 

[Ductape]

Pretty funny ! I call my shop vac R2D2. Nice work.

 

[joes_427_vette]

Nice design. I as probably others are wondering.... Was the tank cut down ? ( doesn't look like a full 40 gallon tank. Judging from the garage door panels it looks about 3' high ) How did you weld the braces in the bottom to hold the concrete ( or fill it ) if the top doesn't come off ? Is the tank structure that thick that the cat. 1 brace will hold with a small strip of weld on top and bottom ? I always thought those tanks were pretty flimsy as they don't weigh much at installation time. Must pay more attention in the future.

 

[JohnDeere4300]

Good looking job!

When did you fill the tank??

 

[Dan22]

Thanks for the compliments guys.

Yes it is a full 40 gallon tank. 20 inches round by 30 or so tall. I filled it with concrete after I had done most of the welding. I cut a "smiley face" hole in the top to fill it, then welded in the old piece to give it a clean look. Hard to cut glass lined tank with a torch. I don't recommend it since it will not make a clean cut. I ended up using a saws-all but that was tough too. Wall thickness was about 1/8".

I left the bottom tank concave surface there to hold the concrete. I never thought of cutting the bottom out to fill it, and I for sure did not want the concrete to slip out of the shell. I just flipped the tank over, welded scraps with gaps and hooks, then filled the bowl until flat. It sits on the dolly frame so even if it cracks it will stay there.

After thinking about it, that would have been much easier to cut a portion of the bottom out to fill it. Would have been one pour then and could have had the flat bottom too. Oh well, next time.

Dan

 

[Dan22]

Nice design. I as probably others are wondering.... Was the tank cut down ? ( doesn't look like a full 40 gallon tank. Judging from the garage door panels it looks about 3' high ) How did you weld the braces in the bottom to hold the concrete ( or fill it ) if the top doesn't come off ? Is the tank structure that thick that the cat. 1 brace will hold with a small strip of weld on top and bottom ? I always thought those tanks were pretty flimsy as they don't weigh much at installation time. Must pay more attention in the future.

I beefed it up at the bottom mount quite a bit. Not shown in the pictures well, but I welded the channel, then splayed out an angle iron brace top and bottom. The horizontal runners take the twist or pulling force.