Pallet Feet for Automotive Stillages: A Guide to Choosing the Right Fit

An automotive stillage can carry hundreds of kilograms of valuable components, but the small components supporting it can make a big difference. Pallet feet help keep the stillage stable, provide clearance for handling equipment and support safe stacking during storage and transport.

Choosing the right pallet feet for automotive stillages is therefore about more than simply finding a foot that fits the bottom of a stillage. The box-section size, foot dimensions, load requirements, stacking arrangement, material and attachment method all need to work together.

In this guide, we’ll explain the key factors to consider when choosing pallet feet for automotive stillages, how pallet feet differ from nesting plugs, and what to check when replacing or specifying feet for a new or existing stillage.

What Are Pallet Feet for Automotive Stillages

Pallet feet are the support components fitted to the bottom of an automotive stillage. They create a stable base, raise the stillage from the floor and provide clearance for forklifts and pallet trucks. This makes the stillage easier to move, stack and store during busy production and warehouse operations.

Their role becomes even more important when the stillage carries valuable automotive parts such as body panels, glass or engine components. These parts may be loaded, unloaded, moved and transferred several times before reaching their final destination, making damage prevention during transportation an important consideration.

Well-fitted pallet feet help keep the stillage stable during this multi-touch handling, reducing unnecessary movement and helping protect the parts inside.

Kirmell supplies a range of steel pallet feet suitable for different stillage and pallet designs, including square and round options. The range includes products such as Square Steel Pallet Feet (KPF1A), Round Mild Steel Pallet Feet (KPF8) and Round Pallet Feet (KPF15), giving manufacturers different shapes and dimensions to consider for their applications.

The right pallet feet should form part of the stillage’s overall design. Their size, height, footprint and fit need to match the frame and the way the stillage will be handled and stacked. Understanding how pallet feet support smarter warehouse storage can help explain their wider role.

Choosing the appropriate Kirmell pallet feet can therefore help provide consistent support throughout repeated use, while an unsuitable fit may affect stability, clearance or stacking.

Why Pallet Feet Matter in Automotive Stillages

Automotive stillages are designed to handle repeated loading, movement and stacking, so every part of the structure needs to do its job properly. Pallet feet may be small, but they play an important role in how the stillage supports loads and behaves during handling.

• Load distribution: Pallet feet help transfer the weight of the loaded stillage to the floor. The right foot size and design can help spread the load across a suitable contact area rather than placing unnecessary pressure on a small point.
• Stability: A suitable footprint gives the stillage a firm base and helps reduce unwanted movement during handling, storage and stacking.
• Stacking: Pallet feet can work with the stillage’s stacking features to help keep units correctly positioned, particularly when pallet feet and nesting plugs are used together.
• Floor clearance: Feet raise the stillage above the floor, creating space underneath the frame. This can help prevent the steel frame from sitting directly on the floor and makes handling easier.
• Forklift and pallet truck access: The clearance created by pallet feet allows forks or pallet truck tines to enter beneath the stillage, making it easier to pick up and move.
• Protection of the stillage frame: Keeping the main frame away from direct floor contact can help reduce wear and damage to the lower sections of the structure during repeated use.
• Consistent positioning when stacking: Correctly sized and positioned feet help each stillage sit in the intended location when stacked. This supports a more consistent and organised storage system.

For automotive applications, these details matter because stillages may be handled many times while carrying valuable components. The pallet feet should therefore be considered as part of the overall stillage design, rather than as a simple add-on component.

Key Requirements for Automotive Stillage Feet

Choosing stillage feet for an automotive stillage requires more than finding a foot that physically fits. The foot needs to suit the stillage’s structure, load, handling method and stacking arrangement. Paying attention to these details helps create a more reliable and practical stillage for repeated use.

1. Load Capacity

For heavy duty automotive stillages, pallet feet transfer the weight of the stillage and its contents to the floor. When selecting a foot, consider the loaded weight of the stillage, how the load is distributed and whether multiple stillages will be stacked.

The foot should be suitable for the loads expected during normal handling and storage. Avoid relying on a generic load rating unless it has been tested or specified for the particular design.

2. Box Section Compatibility

The pallet foot needs to match the box section and geometry of the stillage leg. A foot designed for one section size may not be suitable for another, even if it looks similar.

Before ordering, check the dimensions of the box section, along with the required foot dimensions and fit. Knowing what to measure before buying pallet feet can help when specifying a replacement.

For example, stillage designs may use sections such as 40 × 40 mm, 50 × 50 mm, 60 × 60 mm or 70 × 70 mm, depending on the design and application.

3. Material and Thickness

The material and thickness of the pallet foot should suit the expected loads, working environment and manufacturing method. Steel is commonly used where strength and durability are important, while the appropriate thickness depends on the design and loading requirements.

The operating environment should also be considered. Where stillages are exposed to moisture or conditions that could cause corrosion, the material or protective finish may need additional consideration.

4. Footprint and Stability

The size and shape of the foot’s base determine how it contacts the floor. A suitable footprint can provide a stable foundation for the stillage and help distribute the load over an appropriate area.

The footprint should also work with the overall stillage design and stacking arrangement. A larger base is not automatically better; the dimensions need to suit the available space, frame and handling requirements.

5. Welded vs Other Installation Methods

The way the pallet foot attaches to the stillage is another important specification. Weld-on feet, for example, form part of the frame assembly and need to be positioned and attached correctly.

For welded designs, fabricators should consider the foot’s position, weld access and the connection between the foot and the box section. This is particularly important when installing pallet feet onto a stillage frame. The chosen attachment method should suit the stillage’s construction and intended use.

How to Choose Pallet Feet for an Automotive Stillage

Choosing the right stillage feet becomes much easier when you work through the stillage requirements step by step. Instead of selecting a foot based on size alone, consider how the stillage is built, loaded, moved and stacked.

1. Identify the Box-Section Size

Start by measuring the box section used for the stillage legs. The pallet foot needs to be compatible with the section’s dimensions and geometry to provide the correct fit.

If you are replacing an existing foot, measure the stillage frame as well as the original component where possible.

2. Determine the Required Foot Dimensions

Next, check the required base width, length and overall height. These dimensions affect floor contact, clearance and how the foot fits within the overall stillage design.

For a replacement, using an existing drawing, sample or accurate measurements can help avoid ordering an unsuitable size.

3. Consider Loaded and Stacked Conditions

Think about how the stillage will be used when fully loaded. Consider the weight of the contents, how the load is distributed and whether stillages will be stacked on top of one another.

The pallet feet need to work with the stillage’s intended loading and stacking arrangement rather than being selected in isolation.

4. Check Compatibility With Handling Equipment

Make sure there is enough clearance beneath the stillage for the equipment used to move it. This may include forklifts and pallet trucks.

Consider the fork entry points, floor clearance and the way the stillage is picked up and moved around the production or warehouse environment.

5. Consider Material and Finish

Choose a material and thickness that suit the stillage’s expected use, loads and operating environment. Where exposure to moisture or other corrosive conditions is a concern, the finish or corrosion protection should also be considered.

The right choice will depend on the specific stillage design rather than a one-size-fits-all specification.

6. Confirm the Foot’s Fit and Attachment Method

Before ordering, confirm how the foot will connect to the stillage. For welded designs, check the fit between the foot and box section and make sure the location allows for a suitable weld.

A correctly sized foot is only useful if it can be securely and correctly incorporated into the stillage frame.

7. Check Whether Nesting Plugs Are Also Required

Finally, consider how the stillages will stack. Pallet feet provide the base and floor support, while nesting plugs can help locate one stillage securely on another.

Some automotive stillage designs may benefit from using both. The choice depends on the frame design, stacking arrangement and how the stillages are handled.

Working through these seven points gives you a clearer specification and reduces the risk of choosing a foot that looks suitable but does not properly match the stillage’s design or intended use.

Standard vs Bespoke Pallet Feet for Automotive Stillages

Standard stillage feet can be a good choice when your stillage uses common box-section sizes and standard dimensions. They offer a straightforward option for new builds and repeat replacements where the specification is already known.

Bespoke pallet feet may be better when the stillage has:

• Non-standard box sections
• Legacy or obsolete components
• Unusual base dimensions
• Specific stacking requirements
• High-volume production needs
• Particular manufacturing constraints

For manufacturers producing custom automotive stillages, bespoke components can help maintain compatibility with existing designs without changing the entire frame.

Kirmell’s Pallet Feet

Kirmell can manufacture pallet feet to suit specific stillage requirements. Providing a drawing, dimensions or sample can help determine the right fit for your application, particularly where a standard component is not suitable.

Automotive Applications for Steel Stillage Pallet Feet

Heavy duty automotive stillages are used throughout automotive supply chains to store, move and protect components between different stages of production and distribution. Pallet feet support these stillages during repeated handling, storage and stacking.

Common applications include:

• Automotive component storage and transport
• Engine and powertrain component handling
• Body and chassis components
• Pressed metal components
• Returnable transit packaging
• Parts distribution
• Warehouse storage
• Production-line material handling

The right pallet foot should match the stillage design and handling requirements, whether the stillage is being used on a production line, in a warehouse or throughout a wider returnable packaging system.

What to Specify When Ordering Pallet Feet

Having the right information ready can make it easier to identify a suitable pallet foot and avoid compatibility issues. A buyers’ checklist for pallet feet can also help when preparing your specification.

When requesting a quotation, provide as many of these details as possible:

• Box-section size
• Foot/base dimensions
• Overall height
• Material
• Thickness
• Finish or coating
• Required quantity
• Existing stillage dimensions
• Intended loading and stacking arrangement
• Drawing or CAD file, if available

If you are replacing an existing foot, a clear photograph or sample can also help identify the required specification.
Need pallet feet for your automotive stillages? Send Kirmell your drawing or requirements for a quotation.

Kirmell supplies pallet feet for industrial applications and accepts quote enquiries for specific product and quantity requirements. For automotive stillages, provide your dimensions, drawings or existing component details so the appropriate pallet-feet specification can be discussed.

Need pallet feet for your automotive stillages? Contact Kirmell for a quotation.

FAQs

Conclusion

Choosing the right pallet feet is an important part of designing or maintaining a reliable automotive stillage. The correct fit should match the box section, load, dimensions, stacking arrangement and handling equipment.

For standard requirements, an off-the-shelf foot may be suitable. For custom automotive stillages, non-standard or legacy designs, bespoke pallet feet can provide a better fit and help maintain compatibility.

If you need pallet feet for automotive stillages, Kirmell can help you find the right specification. Send us your drawing, dimensions or requirements to discuss your application and request a quotation.