Plate versus Stem Mount Casters

[TomInNC]

I need to put some casters on a roll around cabinet for the grill. If I had to guess, all in the cabinet will weigh 200-300 pounds tops. The legs are 4x4 posts, and I actually used 6 legs in the design. Initially I was just going to use the casters that I saw in TWW Big Green Egg build (first link). These casters install with threaded inserts in stems. I noticed in the comments, however, that someone had an issue with the stem bending back completely when moving the cart. I contacted a place (caster city) that sells nothing but casters, and they recommended against using stem casters for anything even remotely heavy. They said that for heavy-duty applications that will see a lot of use, you should use plate casters. 

On the plate caster front, it seems like the plate for the 4" heavy duty casters from rockler should fit on the bottom of my leg. I'm a little concerned, however, about how close the mounting holes would be to the edge of the leg. 

 

I asked Rockler about the spacing of the holes in the mounting plate, and this is what they told me: "Looking at the plate long side running left to right.

Holes are elongated 3/8" along the long side of the plate.  Center of hole from the end in is also 3/8",  center to center is 2-7/8". Looking at it narrow part of the plate running up and down Center of hole from the end 7/16".  center to center is 1-13/16". 

 

Do you think that would leave enough "meat" in the leg around the mounting screws? Or would I potentially have an issue with the screws tearing out the side of the leg?

 

 

https://thewoodwhisperer.com/videos/xl-big-green-egg-table/

 

https://www.rockler.com/4-300-lb-heavy-duty-polyurethane-caster

 

 

 

[Tom King]

I used stem casters on the cart I made for a welder and tool cabinet, but they're bolted through angle iron.   In that case there wasn't room for plate mount but the angle iron is plenty strong enough.

[BonPacific]

I think you should be good with those plates into 4x4's. I've never had a problem with any tool/shop cart using similar plates right up to the outside edge (including my former lumber rack). Unless you're really off-roading that thing lateral force on the screws shouldn't be a problem. As I see it any force the screws do encounter is spread across multiple screws via the plate, and as long as they're snugged up the plate also provides a "shoulder" to reduce racking.

[Dave's Not Here]

To each his own but personally I think 4" casters are way over kill for this application. 

[TomInNC]

Thanks. I will give the plate mounts a try. As for the caster size, this seems to be pretty common for large carts that get pushed around a lot. I already factored the caster height into the leg length, so too late now!

[wtnhighlander]

Large wheel diameters are helpful if your patio isn't smooth, like expansion joints or tile joints. As for the plate screws, you might angle the pilot holes slightly in toward center of the leg.

[Coop]

I would drill a couple of extra holes inside from the edge, just to be on the safe side. 

[roughsawn]

Pre drill pilot holes. Should prevent any cracking out the sides.

[TomInNC]

Finally at a point where I am going to install the casters. The new place we are moving too has a brick back patio that is very bumpy, so I went with the 4" casters. The final dimensions on the legs were 3.75 by 3.75, and the pre-drilled mounting holes are little close to the edge of the leg for my liking. I have a ton of scrap left over from the project, so I was trying to think of a way to make a decorative "shoe" that has a larger diameter than the leg base (e.g., maybe 5x5) that I would connect the caster to. Then, I would connect the shoe to the table leg. Is there a woodworking term for what I am trying to do here? I'm coming up empty with my googling. Ideally the shoe would look like a trim piece and not a complete afterthought.

[Wimayo]

I might consider a 1/2" collar around the end of the legs; 4 pieces for each leg epoxied into place with mitered corners and beveled top. These would make the ends of the legs another 1" bigger in both directions and would be strong enough even if the screws ended up going into a seam.

[TomInNC]

Thanks. I think the word I was looking for is "pedestal". The collar idea above should work great. Thanks

[TomInNC]

The casters arrived today. I am looking at the mounting plate, and if I don't expand the leg of the base, the pilot holes would be about 3/4" from the edge of the legs if I don't install the collar described above. Is this cutting it too close, or should that be enough material to hold the screws?

While I like the collar idea, I am running out of material, and I am moving very soon. Not sure I can fit a trip to the hardwood store in before the trucks come, and the movers obviously want this thing on wheels.

[Coop]

I think3/4” is plenty of meat, especially with 4 screws per plate. 

[Wimayo]

3/4" is likely OK. However, for piece of mind, pre-drill for the screws and then clamp some cauls to the outside (where the collar would have been) to apply pressure while you are inserting the screws. This will help prevent splitting.

[Warsnoopy]

I had this same situation when using 4x4s as legs for a work table and called Caster City for help on how to fasten casters to a 4x4 and have enough meat to prevent it from splitting out. 

"Hollow Kingpin casters have a 1/2″ diameter hole in the center of a swivel caster where the stem would normally be.  This design enables you to supply your own bolt for a stem so you can use any length needed for your application.  Hollow Kingpin casters are typically used when there is not enough room on the equipment’s mounting surface to attach a plate.  This caster has a 1/2″ diameter hole for your BOLT."

 

This lets you go down the middle of your 4x4 leg (actually 3.5 x 3.5) with a 1/2" diameter lag bolt , any length or grade you desire.

 

So you would use something like this : https://www.castercity.com/product/stem-casters/4-swivel-caster-maroon-gray-premium-polyurethane-wheel-model-3-2/

And provide your own 1/2" diameter lag bolt.  This solves the problem of trying to tap a hole in the middle of wood for a stem caster, or using a plate caster that has its bolt-hole pattern on the outer edge of your wood , which will cause a split-out failure. 

 

There are more expensive options but I chose this maroon wheel for an overkill solution that doesnt run up the bil.