Engineering Design Project

This project is a custom-built tool storage system designed for a shipping container. The goal is to maximize vertical space, improve organization, and provide quick access to hand tools while keeping them securely stored.

1.25" steel (square stock)

1" steel tubing

Weld wire (for MIG welding)

Metal hooks (tool hangers)

Basic welding equipment

Grinder / cutting tools

Measuring tape and marker

Metal saw or cutoff wheel

Safety equipment (gloves, helmet, eye protection)

Clamps

Sawhorses

The first step in constructing the tool holder is to accurately measure the distance between the hooks and develop a complete design layout. This includes determining the total width, height, and mounting area where the tool holder will be installed. The designs goal is to maximize vertical storage while ensuring tools remain easily accessible and do not interfere with container use. Key design decisions are made at this stage, including the height of the hanging system, the number of tool slots required, and adjustments for long-handled tools such as rakes. Material lengths are also calculated to reduce waste and ensure accurate cutting during fabrication.

Once the design is finalized, the next step is to accurately transfer all dimensions to the material and prepare for fabrication. All steel components are measured based on the design layout, including the 1.25” steel used for the main hanging bars and the 1” round steel tubing to hang the tools on. Each measurement is marked clearly using a tape measure, square, and marker to ensure accuracy and maintain alignment between components. After marking, the steel is cut to size using a metal saw. All cut edges are then deburred to remove sharp edges and improve weld quality.

After all components are cut to size, the pieces are laid out on sawhorses as a stable work platform. Check the alignment of all pieces before welding, and mark expected positions with a marker. The vertical bars, horizontal support, and hook placements are arranged according to the design to ensure correct spacing and orientation. Small adjustments may need to be made, or pieces may need to be recut during this stage. Ensuring everything is properly aligned at this point helps guarantee a straight, level, and structurally sound final product.

Once all components are properly laid out and aligned, tack welding is used to temporarily secure the structure before completing full welds. Small welds are placed at key joints where the vertical bars, horizontal supports, and mounting components meet. This holds the assembly in position while reducing the amount of time it takes to make adjustments if needed. This sets the stage for the final assembly and at this point the project has really come together. It is important to double check and make sure that the alignment of the parts looks visually correct.

Final welding is performed to permanently join the structure. Continuous weld beads are applied at all joints, including connections between the vertical bars, horizontal supports, and mounting components, to ensure maximum strength and durability. It is very important to be aware of what you are touching because the metal can heat up very quickly and you can easily burn yourself if you aren't careful. The weld may warp the metal as well that is why we also tack in the previous step in order to counter act that force. Once welding is complete, all joints are allowed to cool before handling. Any excess weld material or rough edges may be cleaned using a grinder to improve appearance and safety. This step finalizes the structural assembly, creating a rigid and durable tool holder capable of supporting the intended load under regular use conditions.

Once the main structure is fully welded and cleaned, the hooks are installed to create designated tool-holding positions. Hook locations are first measured and marked along the horizontal bars to ensure consistent spacing and proper clearance which is exactly 33 inches apart in this case. The hooks are marked than tacked into place again before completing the final weld.

After the hook installation is complete, the finished tool holder is mounted inside the shipping container. The system is installed using the no-drill hook mounting method to securely attach it to the container structure without causing damage to the walls.Once mounted, all tools are placed onto the holder to verify proper spacing, balance, and retention. Each hook and support is tested under typical loading conditions to ensure the structure can safely support the intended weight without shifting or instability.

After initial assembly and test fitting, the design is evaluated to identify any functional issues or areas for improvement. During this phase, observations are made regarding tool accessibility, overall height, spacing, and stability of the system. Unfortunately, the tools were hanging too low, which reduced accessibility and interfered with usable space beneath the rack. Ultimately it was unsafe in the state it was before so we had to adjust the vertical bars. To correct this, the vertical bars were cut down to shorten their length, effectively raising the overall height of the tool holder.