The next major step is taken. After routing, drilling and sanding the wooden side panels, I could assemble the case with all its parts for the first time. Everything fits, allmost. Minor modifications need to be done, but then I can start with the last step, oiling the wooden side panels and get the rear and bottom panels powder coated. I still don’t know which colour the aluminium parts will get, any ideas?
When this is all done, the final assembling and the wiring of the four PSUs and the eight busboards needs to be done. And that’s it.
I’ll keep you updated.
Here are some impressions from the first assembling:
The works on wooden side panels have started. First time ever using a proper router, amazing tool. Does exactly what I needed. I routed the shape of the panels out of 24mm multiplex wood. This was a step I had a lot of respect for, as I never handled a router before. So I started with an easy straight line and then step by step raised the bar a bit higher. There are two edges where I need to add some wood again, but some dues you have to pay when learning.
Next step will be drilling, sanding, staining the wood and then finishing with oil. I will keep you updated.
Here are some impressions from my first experiences with woodworking and some shots off the drilled bottom and rear panels.
This is actually a simple exercise but if you are not a handyman and have the right tools it might get annoying. This is why I am trying to organise a groupbuy for this side panels.
This is what it is all about. A prototype of a 3U side panel for fixing the rails on a rack (still missing the drillings for fixing). Sure, you can fix the rails directly on the rack, but using the panels is way more elegant.
Assembling a 19 inch case is not rocket science but it has some pitfalls. Especially when you buy the components from eBay or different vendors.
Before you start be aware that there is no standard, not all components from all manufacturers fit together. This post should give you an overview of the components you will need. The construction is based on the Doepfer A-100G6 rackmount cases. The parts of my construction are a mix of Roger and Gie-Tec parts as well as my own power supply (PSU) and busboards.
I can provide you with a complete DIY set for your case or just some parts, just ask for pricing.
Not to get confused, some rack systems use rails with M2.5 threaded strips. You will hardly fit M3 strips in these rails. Please also notice that my rack uses side panels which are already combined with the rack ears as one part. This is usually not the case.
Some rails use M4 threads instead of M5 for the side fixing. The parts of the list below fit perfectly together.
There is also some mechanical work that needs to be done, drilling holes to fit the PSU on the rear panel and filing a big hole to fit in the mains inlet and fuse holder also on the rear panel. But this is it.
List of mechanical rack parts with order numbers from Gie-Tec as of May 2013
4 pcs. 138006 – Rack ears 3HE
2 pcs. 138010 – Side panels 6U
8 pcs. 125010 0432 – Rails type 1, non perforated, l=432mm, 85HP
32 pcs. 493030 0066 – M3x6 Pan head screws, DIN 7985/ISO 7045
5 pcs. M3 Thooth Lock Washers
What really confused me when I started to build my first 19 inch rack was the width of the rails. To build a 19 inch rack with a usable width of 84HP (ca. 427 mm, exact 426.72 mm) you will need 85HP (432 mm, exact 431.8 mm) rails. The rack ears need 2,54 mm space on each side of the rack, as you can see on the following picture.
The busboards will be screwed on the two perforated rails using pan head screws, thooth look washers and square sliding nuts. Don’t worry, the part that is connected to the rail does not carry any contacts. So no risk of short circuit.
List of electrical components
1 pcs. IEC 320 Mains inlet with fuse holder and switch
5 Fully Insulated Receptacles, 6.3 mm
10 Fully Insulated Receptacles, 4.8 mm
5 Insulated Fork Cable Lug
1 Micro Fuse, 230V – 400mA, time lag or slow blow
1m PVC Cabel for internal wiring, H05V-K or H07V-K, green-yellow
1m PVC Cabel for internal wiring, H05V-K or H07V-K, black or brown
1m PVC Cabel for internal wiring, H05V-K or H07V-K, blue
TECHNICAL DISCLAIMER: Please be aware that the power supply carries mains voltage (115 or 230 V AC). According to the safety rules the installation has to be done by qualified personnel only. Please keep that in mind: Danger to Life!
This is a private blog, and it is about sharing experiences. No warranty at all.
This was a major step. Today I got the bottom and rear panels bended. Two main parts of my case construction, which I couldn’t do on my own.
The idea of the case construction is to fix the rear and bottom panels with threaded rods between to wooden side wings. Next up I have to drill several holes to fix the busboards and and PSUs on the panels. The hole for mains inlet with switch and fuse holder needs to be routed. Once the metal work is done the panels will be powder-coated.
Some sketches of the case to visualize the construction. The other main components of the construction are the wooden side wings. These need to be drilled, routed and sanded before they finally get an oil finish. That’s the rough plan for the next weeks.
Some pictures of panels:
If you want to read the full story, here are all the posts: