Mobile Steel Hoist

Project Overview

This hoist was designed to help my grandpa lift heavy equipment in his shop (lawn mower, power washer, etc.). It also became a multi-purpose lifting tool for future builds. The main goal was functionality, safety, and the ability to fabricate the whole system using only scrap steel and basic shop tools.

Design & Constraints

Primary Constraints

• All steel must come from scrap stock available at a local construction scrap dumpster.
• Maximum height limited by shop ceiling fans.
• Must be mobile and stable while lifting.
• Must be buildable with MIG welding and hand tools.

Design Strategy

The design was built around the largest scrap component available: a piece of HSS 4x4x½ tube steel with HSS 8x4x½ welded at both ends. This piece became the main post, with the base being beveled and splayed for stability.

Engineering Calculations

We used statics and strength of materials to estimate the maximum allowable loads based on section modulus, moment of inertia, and weld sizing. Calculations were referenced from the AISC Steel Construction Manual (14th edition).

• Calculated capacity for main post and jib arm based on available sections
• Checked weld sizes for allowable shear
• Compared alternative jib configurations (tube vs. double-angle)

Build Process

Step 1 — Sourcing & Layout

We scavenged for strong, straight steel sections and selected members based on available lengths. The main post set the entire geometry.

Step 2 — Base Beveling & Splayed Legs

We beveled the HSS 8x4x½ base using an angle grinder to splay the legs. This was time-consuming and rough—future builds would use a bandsaw for cleaner cuts.

Step 3 — Jib Arm Welding

We rigged pulleys from the roof frame to lift and align the jib arm. Overhead and flare bevel welds made this stage especially challenging.

Step 4 — Mobility Additions

We mounted rear casters on a channel at the base to avoid drilling into ½” steel. Later, we added handlebars for steering and tested mobility under load.

Gallery (Placeholders)

Lessons Learned

• Beveling large sections with a cutoff wheel is slow and messy—use a bandsaw next time.
• Overhead and flare bevel welds require more practice and prep.
• Designing around scrap materials is powerful but requires flexibility.