Mini Network Rack

Introducing my mini networking rack! This is a miniature networking rack system designed to be printed on a 220x220 bed. Its customizable with all kinds of various small network equipment! If something isn't here, leave a comment with the dimensions and I will try to add it! This is designed to attach to regular 20x20 aluminum extrusion and uses m3 screws and hammerhead nuts to mount all the different devices. There's also a version that uses 2040 and some custom ears to mount into a regular 19" rack so you can mount all your smaller devices instead of using a rack shelf!

Note: raspberry pi cluster is designed for these cases in particular top_low_fan40_poe. I also strongly suggest POE hats if you plan to use this cluster, and a fan is a must (Noctua 40mm fans are GREAT)!

Mounting the shelves

All shelves install with a hammerhead nut and an m3x5 screw. I typically screw the hammerhead nuts in “vertical”, slot it into the extrusion, loosen each screw then re-tighten it. Some shelves have a locking mechanism now, you can use an m3 screw and a washer to lock the equipment in place. The “Universal” Shelves print and glue the side and back pieces in place to keep the equipment from shifting around. You can print the open or closed version depending if you need access to plugs or otherwise on the front of the rack. Want something custom? Leave dimensions in the comments and I'll see if I can add it!

Rack Assembly Instructions:

Mini network rack: 

Bill of Materials:

• 8x 180mm 2020 extrusion (top square and bottom square)
• 4x your choice 2020 extrusion (sets height of mini rack)
• 32x m3x10 screws
• 32x m3 hammerhead nuts
• 8x 2020 corners (printed)
• 1x “1u Blank” (printed, for sizing spacing of extrusion)

Build Instructions:

1. Mount two screws with hammer head nuts on the inner most screws to the 90 (it should look like figure 1 below)
2. Insert one of the “your choice" length extrusions and screw tight. Install a second on the other side in the same manner
3. Repeat for the other 3 “your choice”
4. The width of the rack is critical, the depth matters less, but we can set that later. Build the rest of the cube.
5. Once the cube is built loosen all four of the “left front screws” (This is relative, decide what you want to be the front). Insert an alignment adapter at the top and bottom to appropriate spacing and tighten screws. You may need to loosen the screws on the “back” of you mini rack as well if there is not enough play.
6. You may optionally install the side panels to glamour up your rack
7. Print and mount your shelves!

Figure 1: Proper aluminum extrusion mounting

19 Inch Insert:

Bill of Materials:

• 28x m3 hammerhead nuts
• 28x m3x5 ball head screws
• 4x 19in rack adaptors
• 2x 2040 90 coupler
• 2x 135mm 2020 aluminum extrusion
• 2x 440mm 2020 aluminum extrusion
• 1x 135mm 2040 aluminum extrusion
• 2x 2040 middle mount
• 4x 1U spacing alignment tool

Build Instructions:

1. Use m3x5 screws and hammerhead nuts to mount the mini rack adapter to the top and bottom aluminum extrusions. They should butt up against the inside walls of the 3d printed parts.
2. Mount the vertical 2020 extrusion using the hidden screws and hammerhead nuts on the inside of the rack adapters
3. Using the 2040 T mounts, mount the 2040 extrusion as close to the center of the rectangle you just made, tighten the screws on the 2040 but do not tighten the screws on the 2020. 
4. Loosen all of the front facing screws on the mini rack adapter slightly
5. Now snap in the spacing alignment tools to both the left and right sides of the rack on the top and bottom. Shift around the 2040 and the side pieces as needed until the fit.
6. Pop out the alignment tools, install the adapter in your rack, print your shelves and enjoy!

Power Distribution Unit:

DANGER: This requires you to work with mains voltage. Mains voltage will kill you. If you do not know what you are doing. Maybe skip this one. I am not responsible for any injury.

Bill of Materials:

• 3x 8 port Wago Push Connectors (Amazon US)
• 6x Panel mount US sockets with ground. (Amazon US)
• 1x Fused C14 inlet. (Amazon US)
• 6x heat set inserts (Amazon US)
• 1x Power Distribution Insert
• 1x Power Distribution Lid
• 6x m3x10 screws

Build Instructions:

1. Seriously if you didn't read the warning again, this requires experience with mains voltage, if you are not comfortable doing so, don't build this. I am not responsible for any injury.
2. Read step 1 one more time
3. Fine I shall continue….use wire cutters or flush cuts to cut the sacrificial bridge on each of the locations for the panel mount sockets
4. Install the heat set inserts on the top for the lid, as well as in the large square opening for the power inlet
5. Snap in all 6 panel mount sockets
6. Screw in the inlet with 2 m3x10 screws
7. Wire colors don't always match, please verify your live, neutral, and ground wires, there are multiple standards for wire colors.
8. Connect the live wires together via one wago connector
9. Connect neutrals via another
10. Finally connect grounds with the final wago
11. Verify your wire connections one more time
12. Use the remaining 4 screws to screw the lid on (please don't plug this in with the lid off, there's lots of exposed mains voltage still.)