Roadster Body Buck

Today I built this body buck with an extra shelf supports, and no legs. I’ve got the ceiling height so I’ve decided hoist it up using pulleys to roll the chassis underneath.

Tools

  • Screw Gun
  • Circular Saw
  • Measuring Tape

Materials

  • (3) 48″ x 96″ x 1/2″ Playwood. Some use OSB, and while OSB is cheaper, I found it to be way heavier than standard 1/2″ plywood. It also has a really crappy surface quality  (I used ½ inch thick and it worked great. Additionally, others have used  5/8” thick but indicated it was thicker and heavier than needed.  And while OSB is stronger, it doesn’t make sense since the body itself it only 90lbs and it isn’t being stored outside.
  • (6) 2″ x 4″ x 96″ nominal lumber.
  • Lag Bolts
  • Washers
  • Eyelet Toggles.
  • (4) Pulleys/Blocks (optional). You will only need these if you are hoisting it to the ceiling as we are.
  • (4) caster wheels (optional). It is recommended you get 3 inch diameter or larger, total height including swivel about 4 inches or more.  Don’t go smaller as they will not roll well.
    • (2) 3” locking swivel caster
    • (2) 3” swivel caster
  • (16) #14 size x 1 ¼” wood screws, Philips head,  Check size of holes in wheel swivel.
  • 1-5/8” course thread drywall screws. Small box
  • 2 ½” course thread drywall screws. Small Box
  • (5) 4’ foam water pipe tubing insulation (usually comes in packages of 4 at Home Depot for about $4.00.
  • (16) 10”+ zip ties, to hold foam insulation in place, or you could use some wire instead.

All of this cost $150 or so.

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