Large Format Football Helmet Repair Workstation

This custom Helmet Repair Workstation from LM Cases was designed and built for the University of Cincinnati football program. Rather than simply transporting tools and replacement parts, the case creates a complete mobile workstation designed to keep the equipment needed for helmet service, adjustment and repair organized and immediately accessible on the sideline.

The upper work surface is divided into three sections with hinged UV-protected clear Lexan covers. Beneath the covers is an extensive grid of individual storage compartments designed for small components including screws, washers, snaps, hardware and other helmet repair parts. The clear covers allow the contents of each compartment to remain visible while helping keep small pieces contained during use and transportation. The drawing specifies three hinged Lexan covers over an 11 x 6 compartment grid.

The workstation incorporates a total of 13 drawers in several configurations. The upper and middle drawers use removable marine-grade plastic dividers to organize smaller components, while the four larger lower drawers are divided front-to-back for larger tools and supplies. Each drawer is constructed from 1/2” Baltic Birch plywood, finished with a durable black texture coating and mounted to heavy-duty locking drawer glides. The glides lock in both the fully closed and fully extended positions, helping prevent drawers from opening while the workstation is being moved or closing unexpectedly while technicians are working.

A dedicated power-tool compartment uses a custom-contoured insert designed specifically for a Milwaukee drill, Milwaukee impact driver and Milwaukee rivet gun. Additional enclosed storage compartments provide space for general-purpose tools and supplies. Clear 3/8” Lexan doors allow technicians to visually identify compartment contents without opening each section, while the cleanable HDPE interior provides a durable surface suited to everyday equipment-room and sideline use.

Two large open compartments below the drawer bank provide additional storage for larger items, tool cases, bags and bulk supplies.

Because a workstation of this size can become extremely heavy when fully loaded, the drawer assemblies are built into a separate 1/2” Baltic Birch inner shell rather than attaching the drawer glides directly to the exterior walls of the road case. The internal assembly is isolated from the exterior case with PE foam. This construction keeps drawer-glide fasteners out of the exterior shell while reducing the amount of stress transferred to the drawer mechanisms as the loaded workstation is moved.

The entire workstation rides on LM Cases heavy-duty “Donut” field casters mounted to a 3/4” plywood caster board to distribute the substantial loaded weight across the bottom of the case. A gas-assisted top lid makes the large lid easier to open and close while also helping hold it securely in the open position during use. The overall design measures approximately 53.74” wide x 29.99” deep x 54.08” tall at its maximum outside dimensions.

Designed around the actual workflow of an equipment staff, this workstation combines transportation, organization, parts inventory and a usable repair surface into a single road-ready package. It is an example of the custom workbox construction LM Cases can provide for football equipment departments, athletic programs and professional sports organizations where durability, organization and quick access to tools are critical.