Project DIY 10" Server Rack

This is my project for a portable modular 10" server rack. The size of the rack is determined by the length of the rails. The rack is designed with 4 rails instead of just 2 to make the backplane configurable for those who need extra mounting space on a low rack. The now published project doesn’t have any models for top, bottom and side covers (might be updated at a later date) or any form of trays/blind-plates as these can be found from other makers or you just want to custom make them for your needs...

I've designed my own rails for laser cutting out of sheet metal (in my case 2 mm stainless) and then bending it into an L-shaped rail. The format for the mounting side of the rail follows the specifications of ECIA – EIA/ECA-310 (according to wikipedia entry on rack rails) , and are made for cage-nut fasteners. I've based my design from the look of different commercial rails, but my measurements for the widths of the wings are my own. So i can't guarantee that a commercial rail will work with my top and bottom pieces without some modifications.

For those who wants to try and make your own I’ve included laser cutting files (Autodesk .dxf format) for 3 sizes: 4U/6U/8U (be aware my cutting files still have a dash-dot line for the bend in them that has to be removed before cutting, I can’t for my life find a way to make fusion hide this line on a flat pattern of a sheet metal model), and there's also a parametric Fusion file to make custom size rails. The only parameter that needs changing is 'units', works for any integer number larger than 1. After the unit is set update the flat pattern and export a .dxf file of that to your cutter.

You could probably 3D-print the rails in some appropriate material as well, just export the model and try.

I print my parts in PETG using 3 shells (because of the heatset inserts) and with a 10% infill (grid or cubic). All parts fits on a minis buildplate (the crossbar can be split to fit), but a larger buildplate will probably take more parts in a singel print. On the mini the print time for the top/bottom holders are about 1.5h and a single split crossbar are about 2h.

Update:

Added 3D-printable files for 4U/6U/8U rails for those who wants to try, and also a 1U blind panel.

20260318 - Added 3D-printable files for top, bottom and side covers, and also lasercutting .dxf files for them. These files are to large for the printbed of a mini (and other small size printers).

Assembly:

The M5 inserts go into the top & bottom railholder, 2 for each of the 4 holders. Mount the cage nuts in each rail (at least nuts in the ‘corner’ positions, as they are hard to mount when the railholders are in place). Mount the rails on the railholders with the M5 screws. You now have 2 complete sides.

The M3 insert go into the round holes of the short side of the crossbar. If you intend to have top and bottom plates on your rack also insert the additional insert on the long side of the crossbar. The 258 mm rod goes through the hex channel of the crossbar. If you printed the crossbar in 2 parts also insert the 48 mm rod on the ‘inside’ hex channel and add glue to lock the crossbar. Put the end of the rod in the matching non see-through holes of the railholders and lock them in place with the M3 screws through the holes of the railholder, repeat for all crossbars.

BOM:

Basic Skeleton Version

    4x - rails of desired size

    4x - top & bottom railholder

    4x - crossbar

    8x – M5 heatset inserts

    8x – M5x10 or M5x12 flat head machine screws

    4x – M3 heatset inserts

    4x – M3x16 socket head machine screws

    4x – 3 mm x 258 mm steelrod for stability

    4x – 3 mm x 48 mm steelrod (only needed if you print the crossbar in 2 parts)

    ?? – cage nuts of M4/M5/M6 size depending on configuration

Extended Version

    1x – Basic Skeleton Version

    2x - Topandbottom panel

    2x - Sidepanel

    8x-16x – M3 heatset inserts depending on how/what you want for top and bottom cover

    8x-16x – M3x6 or M3x8 machine screws for fastening desired top/bottom plates

    8x-?x – M4/M5/M6x8 + nuts, for mounting side plates