homemade server rack

[alphastryk]

hey guys... PICTURES!!... lol

The reason I haven't updated this much is because I was in St. Louis this weekend... I even took a picture for you folks here...

Control center at the Anheuser-Busch Budweiser brewery (sorry about the bad quality, apparently my flash decided to go off even though it was disabled...

omg tens of monitors of data

anyways... on to the homemade server rack!

I got home last night, but today I was finally able to make some, ven a lot of progress.

ok... so as you may or may not know, racks are often referred to as '19 inch'. what this actually means is that the horizontal spacing between the mounting holes at each end is approx. 19 inches. the actual width of rackmount equipment varies between 17.5-18 inches, so I had to make that my inside dimension (I went with 18 to make sure everything should fit)

Just as a hint to anyone else who may wish to try this - DON'T get you wood cut at home depot in the lumber section... I did it because my other option was a hacksaw, but the tolerances are like half an inch... a lot of my pieces are way off... :| well, nothing to do but try to work with 'em!

materials and tools (with base frame laid out):

step 1: simple frame for the base:

I realize that the measuring tape fell over while I was getting the camera out, but it is 18 inches... the other dimension is 24" - deep enough to hold most servers with plenty of space for connections (My rackmount case is 21"-ish deep)

another thing to be careful of - very knotty (is that a word?) wood - jammed my drill bit up (I was pre-drilling for my wood screws up until this point, but the bit broke when I tried to take it out.) Unfortunately, I don't have another bit of the correct size, so everything after the bottom and top frames was just wood screws straight into the wood, which caused cracking issues (more on that later)

step 2: put the casters on the bottom frame:

at this point, I began to run into wood cracking/splitting problems... stupid broken drill bit...

step 3: check that dimensions are correct:

looking good!... now on to...

step 4: build top frame (dimension-matched to bottom frame):

I started to have issued with crews stripping out at this point, but I was able to finish them off with a few twists with some pliers... this marked the beginning of an annoying recurring problem.

using some scrap wood and the ground to align, I carefully attached the top frame to the bottom frame. This took a lot of effort and measuring and remeasuring, then sitting on things to hold them down... point is, not any pictures of the process after the initial setup for one side.

step 5: attach the top and bottom frames:

step 6: recheck dimensions:

wow... world's ugliest server rack... xD

server is a bit off (it is the narrowest of my rackmount devices) but it can be made to work...

the switch on the other hand... perfect:

thats all for today... not bad for 2 hours worth of work!

next time I get a chance to work on it, I will mount the surge protector and add a shelf to the top for my network printer...

on another note, I will gladly make a tutorial on this once my project is finished - keep in mind that it will take me a while as I am moving back to school this week.

[SgtM]

Lookin good! +rep.

[goofazoid]

Quick tip on using screws in wood:
Drill your pilot hole in both pieces with a bit that is smaller than the screw (duh! ) and then drill out the hole in the board that the screw head is going to rest against until its the same size as the screw threads.
This is called a "gliding hole technique" (sometimes called a Leg screw technique) and not only is it secure, but it will prevent splitting your wood and will actually pull the bottom board towards the screw head (it make it move towards the top board).
You can also use screws that are smooth from about half way up the shaft to the head.

Also if you are using an electric drill to put your screws in, try going slower with the drill to prevent head stripping. (you can also chance to a Robertson head to prevent this)

Good luck

[yazeed1906]

coming right along...

[Luke122]

Quick tip on using screws in wood:
Drill your pilot hole in both pieces with a bit that is smaller than the screw (duh! )

So then you missed the part where he broke the only bit he had for pilot holes?

Try using a finishing nail to drill pilot holes. Snip off the head of the nail.. the spiral type nails work best.

[goofazoid]

So then you missed the part where he broke the only bit he had for pilot holes?

Try using a finishing nail to drill pilot holes. Snip off the head of the nail.. the spiral type nails work best.

No I caught it, I was explaining a different technique than just single pilot holes.

[alphastryk]

Quick tip on using screws in wood:
Drill your pilot hole in both pieces with a bit that is smaller than the screw (duh! ) and then drill out the hole in the board that the screw head is going to rest against until its the same size as the screw threads.
This is called a "gliding hole technique" (sometimes called a Leg screw technique) and not only is it secure, but it will prevent splitting your wood and will actually pull the bottom board towards the screw head (it make it move towards the top board).
You can also use screws that are smooth from about half way up the shaft to the head.

Also if you are using an electric drill to put your screws in, try going slower with the drill to prevent head stripping. (you can also chance to a Robertson head to prevent this)

Good luck

I broke another drill bit today trying to pre-drill the top piece of wood at least

I was using my drill on the slowest speed that still had enough torque to drive the screws... stupid cheap cordless drill...lol

and whats a robertson head?? I was using phillips heads...

anyways, progress shots:

I noticed that the casters were a jamming up a fair amount when I got the rack back out to work on it...

I can fix that!

mostly better... I think the bearing on one of the casters is warped... ah well, I can live with it...

now to mount the surge protector. I used something called mounting tape I found at home depot a few months back... this stuff is amazing. I have used it to attach a set of speakers to a wall with 2" long strips! the official method of removal is to use a knife to cut between the 2 adhesive portions, then a paint scraper to remove the remains (!?!)

used a 5" long strip to hold the power strip on... that baby ain't goin' nowhere! (seriously, pulling as hard as I can does absolutely nothing)

I know its hard to tell in the picture, but its mounted along the rear right vertical support (since almost all my power plugs are all the way right... how convenient.

now, on to making a printer shelf... a bit of hacksawing scrap to get another horizontal piece and time to get the printer an figure out where it need to go.

Lined up the rear support and marked where it went.

and now for the complete shot of today's work:

(and before anyone asks, yes that is the printer's IP on the front... I do that with all my non-pc network devices... makes setup easier after I move, or when I add new systems that need to have the printer and NAS mapped.)

[goofazoid]

I broke another drill bit today trying to pre-drill the top piece of wood at least

Is it a fairly small size?

and whats a robertson head??

http://en.wikipedia.org/wiki/Robertson_screwdriver

Robertsons are square drive. (sorry I thought I had added that my first post)
You can find them in some sizes in hardware stores.
They seem to get the least slippage of the bit that causes the stripping.
Torx also are good for this, but they seem to be much harder to find.

As far as drills, I use a Craftsman 19.2v cordless drill. I set the torque to medium and the speed to slow. (setting the torque down from max will cause the drill to slip before it can strip the head even if it does slip)
I also have several screw drivers that I cut the handles off and welded them into cheep sockets so that I can use my ratchet to drive them. (works great in places that its hard to get the drill into)

As far as bits, you might look at some of the more expensive ones, and make sure that you are not pushing down too hard on the drill, (let the bit do the work) and don't forget to pull it up often (espc with small sizes) to allow the wood shavings to fall out of the groves.

Goodluck


Oh yeah one more thing... you need to make sure that you have a phillips screwdriver not a reed-prince.
http://en.wikipedia.org/wiki/Screw (under the section: Types of screw drive)

[alphastryk]

ah... thanks...

I believe I am using phillips for everything - the bit that came with the drill (cheap 12v cordless, don;t remember the brand... I didn't buy it...and the screws are definitely phillps... meh... doesn't matter much anymore... prettymuch done...

more update sometime next week most likely... it's moving time...

[alphastryk]

ok, so I'm finally all moved back in here at school, used to classes again and whatnot... and the rack is all setup... unfortunately, I have yet to discover / unpack my camera... :/

so once I find my camera, more pictures... I will also start writing that tutorial this weekend... I have an outline kinda thing, I just need to take the time to type it all up and organize it better.