Here's the design I have in mind for now. Here's some things I want this rack to accomplish:
- Heavy Duty. Each shelf to be able to handle a 75 gallon. As of now, I only have two 55's (hence the 45" long tube offset through each shelf). Also, the tanks are more for breeding purposes now, but would like to keep the option open for more show-style tanks.
- Adaptibility. If feasible, put two of these racks side-by-side (secured by bolts) to hold an 8' tank.
- Transportable. I would like the rack to be assemblable/disassemblable using bolts/nuts.
- Lightweight. Goes along with Transportable - Use lighter material to cut down on weight on floors and transporting.
Each shelf will be welded up as one unit and each leg will be its own unit. The shelves will rest on the triangular gussets (welded to the legs) and will be bolted through the legs, for front-to-back swaying. On the inside of the corners, an L-shaped plate will be welded to the legs. The plate will be drilled and be bolted to the shelves to help with side-to-side swaying.
At this time, I will probably use 1/16" sheet metal to cover each shelf. Each leg will have a plate welded on the bottom with a hole drilled through it. On the back side of the bottom plate (up, inside the tube), I will have a nut welded (unsure of size, but will probably be 1/2"). A bolt will be put it to make the whole stand levelable.
I will paint the rack, probably using a self-etching primer and finishing coat. Also in consideration, non-skid tape put on top of the tubes.
Do I need any other bracing in each shelf to help support the approximately 800 lbs. of weight that will be on each shelf (prevent bowing/warping)?
Is 1/2" clearance on all sides of the shelves enough?
Would longer gussets be better, so that all the pressure wasn't on the joint welds of the shelves (3" or 4" long versus only 2")?
Will 2", 16 ga. tubing be strong enough for the legs?