Drawer End Caps for Husky Workbench

prusaprinters

<h4>The Issue</h4><p>I recently purchased a <a href="https://www.homedepot.com/p/Husky-46-in-W-x-24-5-in-D-9-Drawer-Gloss-Black-Deep-Tool-Chest-Mobile-Workbench-with-Hardwood-Top-H46MWC9V2/313615421">Husky 9-drawer mobile workbench</a> and I loved it immediately except for one thing. The drawers have a soft close mechanism which requires extra opening effort over typical ball bearing drawers. Because of this extra effort, many of the drawers had a “click” sound when pulling on the drawer lip.</p><p>I investigated and found the “click” sound was caused by the aluminum extrusion drawer trim shifting on the steel drawer lip. The plastic trim pieces on each end only press into the inside of the drawer lip, leaving the aluminum extrusion unsecured on the outside. This shift is further impacted by the fit tolerance variance between the bent sheet-metal drawer lip and the extrusion. I actually called up the Husky help line to see if they had replacement parts, etc.. and all they could offer was to return the toolbox completely or bring in the suspect drawers and swap with floor models…This drove me nuts on an otherwise perfect toolbox and I had to fix it...</p><figure class="image image-style-align-center image_resized" style="width:75%;"><img src="https://media.prusaprinters.org/media/prints/60741/rich_content/316f2918-57b1-4ca5-a45a-6dc160bb5679/7e4acd2b-a633-40d8-87ca-13fdb215bd33.jpeg#%7B%22uuid%22%3A%22d5d71694-4bf7-4bbb-8376-3d2baa4bcd56%22%2C%22w%22%3A4032%2C%22h%22%3A3024%7D"></figure><h4>The Fix</h4><p>I designed new end-caps to enclose the aluminum extrusion and constrain its movement relative to the steel drawer lip. Now the outer surface of the extrusion is coupled to the drawer lip and the extrusion shift and resulting clicking is eliminated.&nbsp;</p><figure class="image image_resized" style="width:75%;"><img src="https://media.prusaprinters.org/media/prints/60741/rich_content/53c38b9b-5f64-4a2b-a83a-1552fe36e096/b6c1da13-a2d8-488f-9fc0-7cb92c832dc4.jpeg#%7B%22uuid%22%3A%2220f72b4d-dff0-4a1c-906f-c96943e11c6c%22%2C%22w%22%3A3024%2C%22h%22%3A4032%7D"></figure><figure class="image image_resized" style="width:75%;"><img src="https://media.prusaprinters.org/media/prints/60741/rich_content/a52ef6b2-cee5-43f2-a1d7-6768bec19b90/0dfa1040-484a-47db-ab67-dbee33d12655.jpeg#%7B%22uuid%22%3A%22eaf06eb1-2df4-48c7-baae-a89aa138ffd7%22%2C%22w%22%3A3024%2C%22h%22%3A4032%7D"></figure><figure class="image image_resized" style="width:75%;"><img src="https://media.prusaprinters.org/media/prints/60741/rich_content/3e2cf505-2283-4eda-9d6a-6b861dcc5bec/068499f0-d376-4afd-8006-8e85b68a4b55.jpeg#%7B%22uuid%22%3A%22fd5b9dbb-485a-4f6c-9327-1e9d0c30a3c7%22%2C%22w%22%3A4032%2C%22h%22%3A3024%7D"></figure><h3>Print Instructions</h3><p>Printed in PETG at 0.30mm layer, 10% infill.&nbsp;</p><p>The STL file is a left cap which is mirrored in PrusaSlicer since the caps are side-specific.</p><p>The caps have chamfer features as well as a draft on the inner feature to aid with install, but they are designed to be snug and require a light tap with a rubber or plastic hammer to seat completely.</p><p>I can't confirm if this will fit other Husky workbench &amp; toolbox drawers, but I'd expect these end caps and drawer designs to be widely used across the brand.</p><h5>Before</h5><figure class="image"><img src="https://media.prusaprinters.org/media/prints/60741/rich_content/e16f7dae-14a7-406a-82e0-3fbb7bc32a64/eddf2ac4-ee4f-4201-9708-ad86886f3b9c.jpeg#%7B%22uuid%22%3A%22d81d7fb6-56e0-481c-b797-bc7d0596f927%22%2C%22w%22%3A4032%2C%22h%22%3A3024%7D"></figure><h5>After</h5><figure class="image"><img src="https://media.prusaprinters.org/media/prints/60741/rich_content/591c5f54-5703-4ae6-8b9b-465f790025d5/ceebfe0c-6b55-4bfd-a16e-b2e61fb3bc2a.jpeg#%7B%22uuid%22%3A%22b7ed2397-d365-4ba7-970e-b672dc456da8%22%2C%22w%22%3A3132%2C%22h%22%3A2349%7D"></figure>