Formula Car roller box
Here's a quick one day project anyone could do for under $60. The Formula Car Roller Box is something that I had been making for the past couple of decades that takes no time to build and saves a ton of floor space, your back, and just makes the car easier to work on and store. The wheels can be taken off and stored on both sides of the box making the car narrower, and working on the suspension a breeze. When not working on the car, it could easily be pushed out of the way to a corner of the shop. Plus the box will hold the weight of the fully assembled Formula car. Sold yet? Well here is what you need.
One sheet of 4'x8' 3/4" plywood
8' length of 2"x4"
4' length of 1"x2"
4 swivel castors with a rating of at least 300 lbs. each
2 quarts of paint
Construction is straight forward. The box is approximately 2'x2'x4'. But as you all may know, you have a 1/8" blade width on a circular saw, so in order to limit materials to the one sheet of 4x8 ply wood, reduce your cuts by 1/8" so all the parts will fit. Here's an example, but tweak accordingly.
Assemble the "I" beam using the 2'x2' sides along with the 2'x4' (the shorter one) center beam first. Then square the assembly and install the floor and two 4ft sections of 2"x4". Use gorilla glue or similar product and framing nails or drywall screws, as this is the load bearing structure. Pre drill the 5/16" holes for the castors through the 2x4 and 3/4" ply and flip over to mount the top. The center "I" beam should be sandwiched between the top and bottom panels, glue and nail/screw. I also installed a 1"x2" stiffener in the center of the box, but not necessary, I just wanted to have a separator for the tires, but you can add shelves or anything else you want. Add the castors and paint. I have glued astro turf, carpet, runners, and even stainless steel sheet to cover the top of the box, but Home Depot had a rubber/felt floor mat for 4 bucks that fitted with little trimming.
You're done! Now you may be asking yourself at this point, how in hell am I going to lift the car on the box? Well what I do is to use a 4-5 ft long 4"x4" railroad tie which I span across the top of my rafters perpendicularly in the garage. I then wrap a chain and secure around the 4x4 and one rafter at one end and then the same on the next rafter over. It is a also good idea to box the two rafters with a 2"x8" so they will not squeeze together when lifting. There will now be a length of chain that will span two rafters which you will use for your hoist of come along. The roll bar of a complete formula car with drivetrain is pretty close to the center of gravity, so I use that as my lift point using a min 1000 lb. strap. Lift slowly and check for creaks, and distortion of the rafters. Go slow and see if it will hold the weight. Lift up until the wheels are un-weighted and hold to see if it's ok. Then lift the car up 1-2 inches off the ground and hold. If everything is good, then lift to the required height. It will be a very good idea to have a buddy on your first lift to steady the car, to have another set of eyes, and to move and position the roller box under the car. Now with this said, I have done this many times in my garage. UNDER NO CIRCUMSTANCES AM I SAYING THIS IS EITHER RECOMMENDED OR SUGGESTED FOR YOU TO DUPLICATE. I have no idea of the condition of your garage rafters, nor have performed any engineering study on this method. Proceed at your own risk. Now that we have gotten that out of the way, this is what it looks like, the amazing magic flying car that defies gravity.