Mock up, then measure the hardware
Cardboard before steel. Uses: tape, square, cardboard, the wheels, casters and bin you intend to buy.
- Tape a 48" × 26" outline on the floor and a 44" × 22" body inside it. Make a cardboard side silhouette: 8" hood at 24" tall, 36" cabin at 34" to the counter and 44" to the roof. Roll it through every doorway and gate on the route; the 26" fender width and the removable mirrors are the limits.
- Cut a 34" × 10" cardboard shelf and tape it to the long side you will serve from. Stand on the other side: that is the hinge side. Check the 36" total open width and that two people can work.
- Buy the casters, all four wheels and the ice bin now. Measure the caster mounting height (plate to floor, loaded) and the wheels' true diameter and hub width, and get the bin's cutout template and flange size.
- Write your stack: base ring bottom = caster height; floor top = ring top + ½"; counter ring top = 33¼" (or 34" minus your counter thickness); post length = counter ring top − 1" − ring top. Carry any difference into the steel cut list.
Go / no-go: the cardboard fits the route, the counter height feels right for you, the bin flange fits a 20" × 14" envelope with 1" of counter all round, and your stack is written down.
