19" Server Rack

After seeing a site where someone had made a homemade 19″ server rack and mini-itx server, I just had to do it. It’s not only a cool project, but it involves a lot of stuff I’m interested in, electrical stuff, computers, building, wood working, design, and unix(as you will find out). So let’s get started.

Index

The Plan

The plan is to build a 16U 19″ server rack that is 28″ deep. The extra 3 inches (25″ being a more standard depth) allows for easy access of the wires from the back, and extra room to add smaller rack mount equipment, such as a switch, to the backside of the rack. Check out the blueprints.

Once the rack is done, I will slowly be working on building servers to go into it. My first project of this kind will be moving my ATX server (devnulled is it’s name, and you’re on it right now) to the rack.

The next step would be building a m0n0wall or OpenBSD router. I will probably use some mini-itx motherboard with two nics on it. One will come in right from my modem and the other will be fed to a 16 port 100mbit switch, but I’m leaning more toward a gigabit switch. Money will decide.

Here is a live plan:

  • Cut and build rack box
  • Mount mounting rails
  • Attach finish to edges of rack

The Rack

Here is the rack after cutting the particle board to the sizes in the blueprints below, assembling, and painting the wood black.
Server rack 1

Here is the side of the case, so you can see how deep it is. I have it 28″ because I think the standard depth is 25″ deep, so this allows me to have 3″ of space for wires.
Server rack 2

Here are the rack mounts with the tapped and square holes, on the left, and the aluminum finish I put on the corners.
Server rack 3

Here is the rack after mounting the mounts.
Server rack 4

Showing off the new castor wheels because that’s how we roll…
Server rack 5

Fitting the aluminum finish.
Server rack 6

Mounting the first finish on the rack.
Server rack 7

Here is the rack finished with all of the aluminum finish on the edges.
Server rack 8

Here is the rack with my 8 port KVM.
Server rack 9

Close up picture of the KVM on the rack.
Server rack 10

Supplies and Costs

Here is the current list of supplies that will be changing until the project is done:

  • Rack Case

    • 4′ x 8′ sheet of particle board: $11.79
    • Handles for cases: $2.39 x 4
    • Black spray paint: $0.99 x 2
    • 1/16″ Thick 3/4″ by 36″ angle aluminum: $3.27 x 8
    • 10-32 thumb/hex screws: $0.70 x 8
    • Sack of 50 Cage nuts: $17.95
    • 16U Rail Mounts with tapped and square holes: $56.95
    • Shipping on above two items: $16.00
  • General Rack Accessories and Equipment

Rack total: $149.30
Rack Equipment: $104.29

Blueprints

Below is a generic blueprint you may use to build a similar 16U setup.
blueprint for server rack