I tried finishing up one of the projects last night, building out my work bench so I have something to work on. Was going to use the 1000 frame because of the limited space I have in my garage.
I was planning to just rip some plywood to fit the top section, and cut a separate piece of piece where the side table would be, so in the summer I could place my golf clubs where the side table is, in between the frame. Cut 2x4 and screw them to the underside so it braces against the frame like a cross member. In theory, it would allow me to just have the plywood sit on the frame, not shift around, and I wouldn't have to drill/bolt anything into the frame. In the future, if I find it's not sturdy enough, I can always revisit. Same idea for the bottom shelf.
I also bought some caster wheels that I think fits into the existing plugs on the weber.
I started with:
Frame didn't look too bad, just a little dirty, and a little bit of surface rust. The caster wheels were broken, so I tried get them off. One plug was absolutely seized and couldn't get it off, so started taking the entire frame apart to spray WD-40 inside to loosen it up. As I was taking the frame apart, I found that one bottom cross member frames had rusted on the inside. 1 broken bolt, one thread completed rusted and came out. When I tried drilling out the broken bolt to save the thread, that one fell out too because of rust. So I will use the great info from
HOW TO: Weber Frame Cross Member repair - and purchase a thread insert.
What I thought was a quick job ended up with all these pieces and piles of rust from inside the frame:
But other than the cross member bar, everything else looks like in decent shape, just have to sand off the rust, use rust reformer.
I may have to put this frame on hold for now, and just use one of my other frames to build out my work bench.
If anyone is looking for a bench vise, Blain's Farm and Fleet (not sure if they are only in Wisconsin), has them on sale right now:
6" Machinist Vise, which I plan to add to my bench.