Lost,
Have you thought about mounting the drawer on ball bearings? I have been thinking about adding one to mine to keep my cons in...I have just been trying to figure out the best way to do it.
when i cut the desk apart i kept all of the tracks for the drawers, so i just used them. i thought about ball bearing slides, since you can buy them at any home improvement store now, but i figured that matching the lengths would be hard, since desk drawers are a little longer than kitchen drawers. with the cart loaded the whole thing must weigh somewhere around 400lb, so the cart stays in place when opening the drawer, and i already have it pretty full - tig torch & cable, rod holder & cable, foot pedal & cord, 10lb spool of wire, 1lb spool of wire, couple boxes of tungstens, some gloves, case of beer, quart of tequila, pint of raw ether... not that i need all of that in my welding cart, but... sorry, couldn't resist the fear and loathing reference.
as far as the best way to mount it? well, i looked back at 4shorts cart and it looks like we had the same thoughts - mount it however you can, and then mask it from view with side panels. i welded some flat bar and angle tabs to the front and back of the cart and bolted the drawer tracks to them. i have a 1/4" carriage bolt front and rear on each track and so far it seems to have no issue with the weight. my tracks look to be about 14ga steel bent into a c shape. once everything is installed, just add some decorative sides to cover the hardware. i did have one advantage of course, i started with the drawer so i was able to build the cart in the exact size around the drawer. i guess your alternative would be to make a drawer that fits the cart. if i hadn't been able to come up with a desk i was going to consider a small multi-function sheet metal tool. i'm sure if i had a slip roll, shear and brake, i'd find all sorts of uses for it.
